Ford - Explorer 4wd - Workshop Manual - 2000 - 2000

Factory Workshop Manual Make Ford Model Explorer 4wd Engine and year V8-302 5.0L VIN P SFI (2000) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 9 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 14 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 15 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 16 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P0112 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 21 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0117 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0117 > Page 26 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 31 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 32 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 37 P0125 - P0129: Testing and Inspection P0127 For diagnosis of code P0127 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 P0130 - P0134: Testing and Inspection P0131 For diagnosis of code P0131 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 42 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 47 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis P0140 - P0144: Testing and Inspection For diagnosis of code P0141 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 P0150 - P0154: Testing and Inspection P0151 For diagnosis of code P0151 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 55 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 60 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 68 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 69 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 P0175 - P0179: Testing and Inspection P0175 For diagnosis of code P0175 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 74 P0175 - P0179: Testing and Inspection P0176 For diagnosis of code P0176 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 79 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 80 P0180 - P0184: Testing and Inspection P0182 For diagnosis of code P0182 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 81 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 86 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 87 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 88 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 P0200 - P0204: Testing and Inspection P0201 For diagnosis of code P0201 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 94 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 95 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 96 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 P0205 - P0209: Testing and Inspection P0205 For diagnosis of code P0205 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 101 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 102 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 103 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 104 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 109 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 110 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis P0215 - P0219: Testing and Inspection For diagnosis of code P0217 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 118 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 119 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 125 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 126 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 127 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 128 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 P0305 - P0309: Testing and Inspection P0305 For diagnosis of code P0305 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 133 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 134 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 135 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 136 P0305 - P0309: Testing and Inspection P0309 For diagnosis of code P0309 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to charts P0181 - P0325 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 147 P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 148 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 153 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 161 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 162 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 163 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 164 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 169 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 170 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 171 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 172 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 > Page 181 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 186 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 197 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 202 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 203 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 208 P0455 - P0459: Testing and Inspection P0457 For diagnosis of code P0457 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 213 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of code P0500 refer to system experiencing problems Engine Controls P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 219 Inspection Transfer Case B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Windshield Wiper/Washer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 220 Part 1 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Windshield Wiper/Washer diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 221 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0500 - P0813 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 222 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 223 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0500 - P0813 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 224 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis P0505 - P0509: Testing and Inspection For diagnosis of code P0505 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 232 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to chart P0500 - P0813 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 238 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 239 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis P0605 - P0609: Testing and Inspection For diagnosis of code P0605 refer to chart P0500 - P0813 NOTE 14: Be sure to check for aftermarket performance products before replacing PCM. (If replacement is necessary refer to Flash Electrically Eraseable Programmable Read Only Memory Flash EEPROM.) See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > Page 243 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 249 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 254 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 255 P0705 - P0709: Testing and Inspection P0707 For diagnosis of code P0707 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 256 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 257 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 258 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 P0710 - P0714: Testing and Inspection P0712 For diagnosis of code P0712 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 263 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 264 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 265 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission For diagnosis of code P072x refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 270 Note: "x" = any number 0 thru 9 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 271 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 272 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to chart Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 273 P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 274 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0722 ( P 0722 ) For diagnosis of code P0722 refer to chart P0722-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 275 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729, ( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis P0725 - P0729: Testing and Inspection For diagnosis of code P072x refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart P0722-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 283 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 284 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart P0722-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 285 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 P0750 - P0754: Testing and Inspection P0750 For diagnosis of code P0750 refer to chart P0722-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 290 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 291 P0750 - P0754: Testing and Inspection P0751 For diagnosis of code P0751 refer to chart P0722-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 292 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 P0755 - P0759: Testing and Inspection P0755 For diagnosis of code P0755 refer to chart P0722-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 297 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 298 P0755 - P0759: Testing and Inspection P0756 For diagnosis of code P0756 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 299 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 P0780 - P0784: Testing and Inspection P0781 For diagnosis of code P0781 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 304 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 305 P0780 - P0784: Testing and Inspection P0782 For diagnosis of code P0782 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 306 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 307 P0780 - P0784: Testing and Inspection P0783 For diagnosis of code P0783 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 308 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis P0810 - P0814: Testing and Inspection For diagnosis of code P0812 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P0815 - P1169 NOTE 1: DTC 1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and continue as directed. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 318 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 324 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis P1110 - P1114: Testing and Inspection For diagnosis of code P1112 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 > Page 332 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 337 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 338 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 343 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 344 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 345 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 350 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 351 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 356 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 361 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 362 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 367 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 373 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1180 - P1460 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 374 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1180 - P1460 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 379 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 380 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 381 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 389 P1245 - P1249: Testing and Inspection P1246 For diagnosis of code P1246 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis P1260 - P1264: Testing and Inspection For diagnosis of code P1260 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis P1270 - P1274: Testing and Inspection For diagnosis of code P1270 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 400 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 401 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 416 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 417 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 423 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 428 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 429 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 430 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 P1410 - P1414: Testing and Inspection P1413 For diagnosis of code P1413 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 435 P1410 - P1414: Testing and Inspection P1414 For diagnosis of code P1414 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444, ( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450 refer to the system experiencing the problem. Computers and Control Systems Refer to Pinpoint Test HX18. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests HX: Evaporative Emission (EVAP) Monitor and System If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 443 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 448 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 449 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 450 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 451 P1460 - P1464: Testing and Inspection P1464 For diagnosis of code P1464 refer to system experiencing problems Engine Controls P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 452 Inspection Heating and Air Conditioning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Heating and Air Conditioning diagnostic information, See: Heating and Air Conditioning/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis P1475 - P1479: Testing and Inspection For diagnosis of code P1479 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 467 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 468 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1461 - P1641 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 469 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 470 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 475 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 P1510 - P1514: Testing and Inspection P1512 For diagnosis of code P1512 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 > Page 480 P1510 - P1514: Testing and Inspection P1513 For diagnosis of code P1513 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 485 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 486 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 487 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 P1535 - P1539: Testing and Inspection P1537 For diagnosis of code P1537 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 495 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis P1605 - P1609: Testing and Inspection For diagnosis of code P1605 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to chart P1461 - P1641 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 513 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 514 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to chart P1461 - P1641 NOTE 18: DTC 1636 indicates the PCM has lost communication withthe Inductive Signature Chip. Replace the PCM (refer to Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 515 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 516 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to chart P1461 - P1641 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 517 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis P1640 - P1644: Testing and Inspection For diagnosis of code P1641 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 525 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 P1700 - P1704: Testing and Inspection P1702 For diagnosis of code P1702 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 531 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 532 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 533 P1700 - P1704: Testing and Inspection P1704 For diagnosis of code P1704 refer to chart P0705-P1704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 534 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 Manual Transmission For diagnosis of code P1705 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission For diagnosis of code P1705 refer to chart Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 539 P1636-P1714 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 540 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 P1710 - P1714: Testing and Inspection P1710 For diagnosis of code P1710 refer to chart P1636-P1714 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 545 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 546 P1710 - P1714: Testing and Inspection P1711 For diagnosis of code P1711 refer to chart P1636-P1714 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 547 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 548 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart P1636-P1714 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 549 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 550 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart P1636-P1714 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 551 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 For diagnosis of code P1715 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 556 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 557 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 558 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > P1728 P1725 - P1729: Testing and Inspection P1728 For diagnosis of code P1728 refer to chart P1728-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > P1728 > Page 563 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > P1728 > Page 564 P1725 - P1729: Testing and Inspection P1729 For diagnosis of code P1729 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 P1740 - P1744: Testing and Inspection P1740 For diagnosis of code P1740 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 569 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 570 P1740 - P1744: Testing and Inspection P1741 For diagnosis of code P1741 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 571 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 572 P1740 - P1744: Testing and Inspection P1742 For diagnosis of code P1742 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 573 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 574 P1740 - P1744: Testing and Inspection P1743 For diagnosis of code P1743 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 575 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 576 P1740 - P1744: Testing and Inspection P1744 For diagnosis of code P1744 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 577 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 582 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 583 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart P1715-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 584 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis P1750 - P1754: Testing and Inspection For diagnosis of code P1751 refer to chart P1728-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis > Page 588 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1755 - P1759, ( P1756 P1757 P1758 1755 1756 1757 1758 1759 ) > System Information > System Diagnosis P1755 - P1759: Testing and Inspection For diagnosis of code P1756 refer to chart P1728-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1755 - P1759, ( P1756 P1757 P1758 1755 1756 1757 1758 1759 ) > System Information > System Diagnosis > Page 592 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1760 P1760 - P1764: Testing and Inspection P1760 For diagnosis of code P1760 refer to chart P1728-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1760 > Page 597 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1760 > Page 598 P1760 - P1764: Testing and Inspection P1763 For diagnosis of code P1763 refer to chart Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1760 > Page 599 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1760 > Page 600 P1760 - P1764: Testing and Inspection P1764 For diagnosis of code P1764 refer to chart Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1760 > Page 601 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1765 - P1769, ( P1766 P1767 P1768 1765 1766 1767 1768 1769 ) > System Information > System Diagnosis P1765 - P1769: Testing and Inspection For diagnosis of code P1767 refer to chart P1728-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1765 - P1769, ( P1766 P1767 P1768 1765 1766 1767 1768 1769 ) > System Information > System Diagnosis > Page 605 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 610 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 611 P1780 - P1784: Testing and Inspection P1783 For diagnosis of code P1783 refer to chart P1728-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 612 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804, ( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis P1800 - P1804: Testing and Inspection For diagnosis of code P1804 refer to system experiencing problems Instrument Panel Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804, ( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis > Page 617 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Transfer Case B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 P1805 - P1809: Testing and Inspection P1806 For diagnosis of code P1806 refer to system experiencing problems Instrument Panel Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 622 - For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Transfer Case B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 623 P1805 - P1809: Testing and Inspection P1808 For diagnosis of code P1808 refer to system experiencing problems Instrument Panel Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 624 - For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Transfer Case B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814, ( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis > P1810 P1810 - P1814: Testing and Inspection P1810 For diagnosis of code P1810 refer to system experiencing problems Instrument Panel Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814, ( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis > P1810 > Page 629 - For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Transfer Case B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814, ( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis > P1810 > Page 630 P1810 - P1814: Testing and Inspection P1812 For diagnosis of code P1812 refer to chart B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1815 - P1819, ( P1816 P1817 P1818 1815 1816 1817 1818 1819 ) > System Information > System Diagnosis P1815 - P1819: Testing and Inspection For diagnosis of code P1815 refer to chart B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 P1820 - P1824: Testing and Inspection P1820 For diagnosis of code P1820 refer to chart B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 638 P1820 - P1824: Testing and Inspection P1822 For diagnosis of code P1822 refer to chart B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 639 P1820 - P1824: Testing and Inspection P1824 For diagnosis of code P1824 refer to chart B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829, ( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 P1825 - P1829: Testing and Inspection P1826 For diagnosis of code P1826 refer to chart B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829, ( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 > Page 644 P1825 - P1829: Testing and Inspection P1828 For diagnosis of code P1828 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1830 - P1834, ( P1831 P1832 P1833 1830 1831 1832 1833 1834 ) > System Information > System Diagnosis P1830 - P1834: Testing and Inspection For diagnosis of code P1830 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839, ( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 P1835 - P1839: Testing and Inspection P1836 For diagnosis of code P1836 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839, ( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 > Page 652 P1835 - P1839: Testing and Inspection P1837 For diagnosis of code P1837 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839, ( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 > Page 653 P1835 - P1839: Testing and Inspection P1838 For diagnosis of code P1838 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1845 - P1849, ( P1846 P1847 P1848 1845 1846 1847 1848 1849 ) > System Information > System Diagnosis P1845 - P1849: Testing and Inspection For diagnosis of code P1846 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854, ( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis > P1850 P1850 - P1854: Testing and Inspection P1850 For diagnosis of code P1850 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854, ( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis > P1850 > Page 661 P1850 - P1854: Testing and Inspection P1854 For diagnosis of code P1854 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869, ( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis > P1866 P1865 - P1869: Testing and Inspection P1866 For diagnosis of code P1866 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869, ( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis > P1866 > Page 666 P1865 - P1869: Testing and Inspection P1867 For diagnosis of code P1867 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1870 - P1874, ( P1871 P1872 P1873 1870 1871 1872 1873 1874 ) > System Information > System Diagnosis P1870 - P1874: Testing and Inspection For diagnosis of code P1874 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1875 - P1879, ( P1876 P1877 P1878 1875 1876 1877 1878 1879 ) > System Information > System Diagnosis P1875 - P1879: Testing and Inspection For diagnosis of code P1875 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1890 - P1894, ( P1891 P1892 P1893 1890 1891 1892 1893 1894 ) > System Information > System Diagnosis P1890 - P1894: Testing and Inspection For diagnosis of code P1891 refer to chart P1828-P1891 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis P1900 - P1904: Testing and Inspection For diagnosis of code P1900 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 686 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 690 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 691 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 694 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 695 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 696 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 697 Alarm Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 698 Alarm Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 699 Alarm Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 703 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 712 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 713 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 714 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 715 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 716 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 717 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 718 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 719 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 720 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: Recalls Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Multifunction Electronic Control Modules: Customer Interest Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 730 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 736 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 737 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 738 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 739 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 740 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 741 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 742 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 743 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 744 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: All Technical Service Bulletins Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer Inaccurate/Inoperative Multifunction Electronic Control Modules: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer Inaccurate/Inoperative > Page 753 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Multifunction Electronic Control Modules: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 759 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 765 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 766 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 767 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 768 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 769 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 770 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 771 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 772 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 773 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: All Technical Service Bulletins Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 778 Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality Module 2.3-3.3 Nm Battery Ground Cable Screws 7-10 Nm GEM/CTM Screw 1.6-2.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 779 Multifunction Electronic Control Modules: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 780 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 783 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 784 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 786 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 789 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 791 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 792 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 793 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 796 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Multifunction Electronic Control Modules: Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 798 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 799 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 800 Diagram 59-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 801 Diagram 59-3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 802 Diagram 59-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Diagram 59-5 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 804 Diagram 59-6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 805 Multifunction Electronic Control Modules: Description and Operation The multifunction modules consist of the following: ^ generic electronic module (GEM)/central timer module (CTM) ^ remote anti-theft personality (RAP) module The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated locks systems. The GEM/CTM controls the following features: ^ wiper/washer (front/rear) ^ warning chime ^ battery saver ^ illuminated entry and courtesy lamps ^ driver one touch down power window (GEM only) ^ accessory delay ^ 4 wheel drive (GEM only) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 806 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic (GEM)/Central Timer (CTM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1 Remove the screw. 2 Disconnect the four connectors from the GEM/CTM. 3 Remove the GEM/CTM. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 809 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 810 Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft Personality (RAP) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static charges, damage may result. 2. Remove the LH rear quarter trim panel. 3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors. 4. Remove the two RAP module fasteners. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 811 5. Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 817 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 818 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 820 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 821 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 823 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 824 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 825 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 826 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 827 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 831 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 832 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 833 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 840 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 841 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 842 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the jack storage panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the parking aid module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 849 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 850 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 852 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 855 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 857 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 858 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 859 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 861 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 863 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 864 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 865 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 869 Remote Anti-Theft Personality (RAP) Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 870 Remote Anti-Theft Personality (RAP) Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 871 Remote Anti-Theft Personality (RAP) Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 875 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 876 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models Power Door Lock Relay: Testing and Inspection Two Door Models Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 879 Power Door Lock Relay: Testing and Inspection Four Door Models Driver Door Unlock Relay Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 880 Door Lock/Unlock Relays Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams Power Seat Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 884 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information Power Seat Control Module: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information > Page 887 Power Seat Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 888 Power Seat Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Remove the Driver Seat Module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. INSTALLATION CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 889 1. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left > Page 894 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 895 Seat Heater Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Disconnect the heated seat module electrical connector. 4. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 896 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Install the heated seat module. 2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Electronic Brake Control Module: Customer Interest Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 906 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Electronic Brake Control Module: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 912 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 913 Electronic Brake Control Module: Specifications Anti-lock brake control module bolts 1.8 - 1.9 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 914 Electronic Brake Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 915 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 916 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 917 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 918 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the scan tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 919 1. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 925 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 926 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 927 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 928 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 929 Blower Motor Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay Compressor Clutch Relay: Locations Compressor Clutch Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 934 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 935 Compressor Clutch Relay: Locations Compressor Cut-Off Relay Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 936 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 937 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 946 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 952 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 957 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 958 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 964 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 965 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 968 Control Module HVAC: Locations Blower Motor Speed Control Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 969 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 972 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 973 Control Module HVAC: Description and Operation The blower speed control is located on the evaporator housing in the engine compartment. - The function of the blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - The blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 980 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 981 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 982 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 983 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 984 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 985 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 986 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 987 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 988 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 989 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 990 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 994 Audible Warning Device Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 995 Audible Warning Device Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 996 Audible Warning Device Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation Fuel Gauge Module: Description and Operation NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 1000 Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 1001 Fuel Gauge Module: Service and Repair Service and Repair The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and must be replaced as a set. For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 1005 Instrument Panel Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 1006 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 1007 Instrument Panel Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations Panel Illumination Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1011 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1012 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1013 Panel Illumination Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1014 Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1015 Panel Illumination Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1020 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1021 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since the last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor only select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Input: ^ Sleep/awake mode status. Feature Output: ^ Battery saver relay control (open circuit in sleep mode, grounded when awake). For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1022 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1023 Battery Discharge Protection Relay: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolts 3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 1027 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 1028 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 1029 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the daytime running lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 1033 Exterior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 1034 Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 1035 Exterior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1039 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations > Page 1043 Headlamp Dimmer Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 1047 Headlamp Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 1048 other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1052 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1053 Horn Relay: Testing and Inspection Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1054 ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 Illuminated Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 1074 Illuminated Entry Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 1075 Illuminated Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 1076 Illuminated Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 1080 Interior Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1084 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1098 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1099 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1100 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1105 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1106 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1107 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1108 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1109 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1110 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1111 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1112 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1113 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1114 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1115 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1116 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1119 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1120 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1121 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1122 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1125 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1126 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1127 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1128 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1129 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1130 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1131 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1132 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1133 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1134 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1135 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1136 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 1147 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 1148 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1154 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1155 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 1160 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 1161 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1167 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1168 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1169 Powertrain Control Module: Specifications Powertrain Control Module Bolt 6 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1170 Powertrain Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1171 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1172 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1173 Part (2 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1174 Part (3 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1175 Powertrain Control Module: Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1176 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 1179 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1183 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1184 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1189 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1190 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1191 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1195 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1196 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module Bracket 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1201 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1202 Air Bag Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1203 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1204 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL WARNING: ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the right hand cowl side trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1207 3. Disconnect the Restraints Control Module (RCM). 1 Slide the two RCM electrical connector locking clips down to disengage them. 2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical connectors. 4. Remove the RCM with bracket. 1 Remove the three RCM bracket retaining bolts. 2 Remove the RCM with bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1208 1. Follow the removal procedure in reverse order. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1209 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1210 LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J" Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts must be installed as outlined in this procedure. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1218 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1219 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1220 Starter Relay: Service Precautions WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1221 Starter Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1222 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. 1. Disconnect the battery ground cable. 2. Disconnect the starter motor solenoid relay switch wiring. 1 Remove the protective cover. 2 Disconnect the push-on electrical connector. 3 Remove the nuts. 4 Remove the cable. 3. Remove the starter motor solenoid relay switch. 1 Remove the engine sensor/generator wires. 2 Remove the bolts and ground wire. 3 Remove the starter motor solenoid relay switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 1228 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1232 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1233 Suspension Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1234 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1235 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 1262 Control Module: Description and Operation The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake depressed and the transmission must be in NEUTRAL. The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect the speed of the front and rear driveshafts. This input is used by the generic electronic module (GEM) primarily to control A4WD operation. The throttle position output signal is provided to the GEM from the powertrain control module (PCM). This signal is used by the GEM in controlling the A4WD clutch. The shift motor sense plate an integral part of the electric shift motor informs the GEM to the position of the transfer case. The digital TR sensors are located on the LH side of the transmission; these sensors inform the GEM when the transmission is in the neutral position. The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the HIGH range (A4WD 4HIGH) and LOW range positions. The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes. The solid state clutch relay is used to activate the A4WD clutch within the transfer case. System Function Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of time the clutch is turned on) which allows for the slight difference between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions the GEM will increase the duty cycle in order to prevent or control slip: ^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position). Feature inputs: ^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch (manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^ Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate position inputs A B C D. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4 shift motor relay outputs. Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature inputs: ^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD mode switch. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 1263 ^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated). When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h (3 mph) the brake is applied and the transmission is in NEUTRAL. Feature inputs: ^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^ Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage when brake is depressed open circuit when not activated). ^ Digital transmission range sensor (ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input (manual transmission only). Feature outputs: ^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on baftery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 1264 Control Module: Service and Repair AUTOMATIC FOUR WHEEL DRIVE (A4WD) Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives Throttle Position Information From the PCM Only. Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Depower the supplemental restraint system (SRS). 2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc 3. Remove the center instrument panel finish panel. 1. Remove the screws. 2. Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the GEM/CTM. 1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. 2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 Four Wheel Drive Selector Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1282 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1283 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1284 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1289 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1290 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1291 Schematic Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1297 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1298 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1299 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1300 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1301 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1302 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1303 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1304 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1305 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1306 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1307 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1308 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1309 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1310 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1311 Power Window Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1312 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1313 Power Window Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 1317 Power Window Relay: Description and Operation LH Front Window Regulator Control Switch Inputs Table The GEM controls manual down and OTD window movement with the OTD relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 1318 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1325 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1326 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1327 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1328 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1329 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1330 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1331 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1332 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1333 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1334 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 1339 Windshield Washer Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 1340 Windshield Washer Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 1341 Windshield Washer Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 1346 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1347 Windshield Washer Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1348 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1357 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1358 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1359 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1360 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1361 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1368 Wiper Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1369 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1370 Wiper Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1375 Wiper Relay: Locations Rear Wiper Up Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1376 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1377 Wiper Relay: Locations Rear Wiper Down Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1378 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1379 Wiper Relay: Locations Wiper High Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1380 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1381 Wiper Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1382 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1383 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1384 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1385 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1386 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1387 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1388 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1389 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1390 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 1391 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 1392 Wiper Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 1393 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 1400 Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 1405 Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1414 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1415 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1421 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1422 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1423 Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor 160 cm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1424 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1425 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 1429 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 2. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connector. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the instrument panel lower steering column cover. 1 Remove the screws. 2 Remove the instrument panel lower steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 1430 5. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 6. If equipped, position the column gearshift lever aside. 7. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the instrument cluster finish panel. ^ Disconnect the electrical connector. 8. Remove the parking aid switch. 1 Remove the screws. 2 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair Remote Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel controls. 1 Carefully remove the steering wheel controls. 2 Disconnect the steering wheel controls. NOTE: The steering wheel is leather wrapped and should be protected when removing the steering wheel controls. INSTALLATION 1. Install the steering wheel controls. 1 Connect the steering wheel controls. 2 Install the steering wheel controls. 2. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 1440 OASIS CODES: 201000, 201200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch 4 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 1445 Power Door Lock Switch: Diagrams Power Door Lock Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1448 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1449 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1450 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1454 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1455 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1456 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 1461 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 1464 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch Power Seat Switch: Testing and Inspection Seat Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch > Page 1467 Power Seat Switch: Testing and Inspection Seat Regulator Control Switch Remove the seat regulator control switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket Power Seat Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1470 5. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 6. Unhook the side shield from the seat latch. 7. If equipped, disconnect the heated seat switch electrical connector. 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1471 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1472 Power Seat Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1473 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1474 9. If equipped, disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left > Page 1479 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket Seat Heater Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1482 5. Release the side shield clips. 6. Disconnect the heated seat switch electrical connector. 7. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1483 Seat Heater Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1484 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1485 9. Disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1495 Trunk / Liftgate Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1496 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations > Page 1501 Acceleration/Deceleration Sensor: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the nuts. 3. Unclip the fuel filter from the vehicle frame. 4. Remove the G-switch. 1 Disconnect the G-switch electrical connector. 2 Remove the G-switch. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations > Page 1502 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1506 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake pressure switch 11-14 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel ......................................................................................................................... 2.1-2.9 Nm (19-25 ft. lbs) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 1519 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Remove the rotor shield. 2. Disconnect the front anti-lock brake sensor electrical connector. 3. Unclip the front anti-lock brake sensor wire from the vehicle frame. 4. Remove the bolt. 5. Remove the front anti-lock brake sensor. 1 Remove the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1522 2 Remove the front anti-lock brake sensor. Installation 1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1523 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1529 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1530 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 1533 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 1534 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Partially drain the cooling system. For additional information, refer to Cooling System. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 8-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 1538 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1552 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1553 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1554 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1555 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1556 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1557 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1558 Attachment III - Technical Information Table of Contents Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1559 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1560 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1561 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1562 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1563 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1564 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1565 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1566 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1567 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1568 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1569 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1570 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1571 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1572 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1573 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1574 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1575 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1576 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1577 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1582 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1592 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1593 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1594 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1595 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1596 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1597 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1598 Attachment III - Technical Information Table of Contents Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1599 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1600 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1601 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1602 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1603 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1604 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1605 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1606 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1607 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1608 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1609 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1610 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1611 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1612 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1613 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1614 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1615 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1616 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1617 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1622 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1623 Brake Switch (Cruise Control): Specifications Deactivator Switch 15-20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 1626 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1627 Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1628 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1637 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1638 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1639 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1640 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1641 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1642 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1643 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1644 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1645 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1646 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1647 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1648 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1649 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1650 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1651 Owner Letter Owner Letter not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Locks Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Locks Lock Service Packages Available > Page 1655 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Locks Lock Service Packages Available > Page 1656 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Locks Lock Service Packages Available > Page 1657 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Locks Lock Service Packages Available > Page 1658 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Locks Lock Service Packages Available > Page 1659 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1662 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1663 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1664 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1674 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1675 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1676 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1677 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1678 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1679 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1680 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1681 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1682 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1683 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1684 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1685 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1686 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1687 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-20-3 > Oct > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1688 Owner Letter Owner Letter not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > System Information > System Diagnosis > P1150 > Page 1692 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > System Information > System Diagnosis > P1150 > Page 1693 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 1707 Cruise Control Switch: Specifications Speed Control Actuator Switch Screws 6.5-7.5 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 1708 Cruise Control Switch: Service Precautions CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 1709 Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio Cruise Control Switch: Service and Repair Without Remote Audio REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switches. 1 Remove the screws. 2 Disconnect the electrical connector then remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio > Page 1712 Cruise Control Switch: Service and Repair With Remote Audio REMOVAL 1. Disconnect the battery ground cable. 2. Separate the speed control actuator switch out of the steering wheel. CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. 3. Remove the speed control actuator switch. 1 Disconnect the speed control actuator switch electrical connector. 2 Remove the speed control actuator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn its strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 12-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1717 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1718 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1719 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1727 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1734 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the plenum assembly air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 1743 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 1749 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Cycling Switch 324 kPa Close Minimum A/C Cycling Switch 152 kPa Open Minimum Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1753 Refrigerant Pressure Sensor / Switch: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1754 Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1755 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1756 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 1759 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - (SCP) communication. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 1760 Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1764 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1765 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1766 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 1771 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 1775 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1779 Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1780 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 1787 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1792 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications Reversing Lamp Switch: Specifications Backup Lamp Switch 25-35 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 1796 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 1797 Reversing Lamp Switch: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 1798 Reversing Lamp Switch: Service and Repair REMOVAL 1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1802 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1803 Brake Light Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1804 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the brake pedal position (BPP) switch connector. 2. Remove the BPP switch 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1813 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1814 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1815 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1816 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1817 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1818 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1819 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1820 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1821 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1822 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1823 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 1824 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: Customer Interest Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 1830 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 1836 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1841 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1842 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1843 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1844 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1845 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1846 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1847 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1848 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1849 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1850 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1851 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1852 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 1858 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1864 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1865 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1866 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1867 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1868 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1869 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1870 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1871 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1872 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1873 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1874 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1875 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 1876 Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 1877 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 1881 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications Fog/Driving Lamp Switch: Specifications Fog Lamp Switch Mounting Bezel Screws 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1885 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1886 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1887 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 3 Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1888 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1892 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1893 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1894 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1895 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1899 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1900 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1901 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1902 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Specifications Main Light Switch: Specifications Head Lamp Switch Screws 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Specifications > Page 1906 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Main Light Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 Main Light Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1922 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1924 Main Light Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1925 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1926 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening cover reinforcement; refer to Dashboard. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the cluster instrument panel finish panel. 5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1927 6. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn blow switches are underneath the driver side air bag module in the steering wheel. The switches are powered through the air bag sliding contact and ground through the steering column. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 1931 Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag; refer to Air Bag Systems. 2. Remove the switches. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the attaching bolts from the switches and remove the switches. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the interior lamp switch electrical connector. 2 Remove the interior lamp switch. ^ Push inward; rotate counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1938 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1939 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1940 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1941 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1942 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1943 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 1948 OASIS CODES: 201000, 201200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1954 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1955 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1956 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1957 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1966 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1967 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1968 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1969 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1970 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1971 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1972 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1973 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1974 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1975 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1976 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1977 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1978 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1984 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1985 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1986 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1987 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1988 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1989 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1990 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1991 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1992 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1993 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1994 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1995 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1996 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 1997 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 1998 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 1999 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2000 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 2003 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 2004 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 2008 Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2012 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 2016 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2017 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Partially drain the cooling system. For additional information, refer to Cooling System. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2021 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2022 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 2025 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 2026 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2036 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2037 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2038 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2042 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2043 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2047 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2055 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2056 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2057 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2058 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2059 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2060 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2061 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2062 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2063 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2064 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2065 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2066 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2067 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2068 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2069 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 2070 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations > Page 2073 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2076 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2077 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2079 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2080 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 2091 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 2092 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The front HO2S: ^ creates a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the PCM used to calculate catalytic converter integrity. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 2093 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 2094 Syncro Positioning Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2098 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2099 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2100 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2101 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2105 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2106 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2107 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2111 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2112 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2113 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2114 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2115 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2116 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 Diagram 64-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2137 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2142 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2143 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2144 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 2145 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2150 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2151 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2152 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2153 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2160 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2161 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2165 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2166 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2167 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2177 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2178 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2179 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2180 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2181 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2182 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2183 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2184 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2185 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2186 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2187 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2188 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2189 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2195 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2196 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2197 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2198 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2199 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2200 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2201 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2202 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2203 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2204 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2205 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2206 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2207 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2208 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2209 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2210 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2211 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 2214 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 2215 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2219 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2220 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 2223 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 2224 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2233 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2234 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2235 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2236 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2237 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2238 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2239 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2240 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2241 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2242 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2243 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2244 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2245 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2251 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2252 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2253 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2254 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2255 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2256 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2257 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2258 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2259 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2260 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2261 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2262 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 2263 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2269 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2270 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2271 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2272 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2273 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2276 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2277 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2278 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2282 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Impact Sensor: Recalls Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2296 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2297 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2298 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2299 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 01-5-4 > Mar > 01 > Recalls for Impact Sensor: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Impact Sensor: Recalls Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 01-5-4 > Mar > 01 > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 01-5-4 > Mar > 01 > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2314 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 01-5-4 > Mar > 01 > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2315 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 01-5-4 > Mar > 01 > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2316 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 01-5-4 > Mar > 01 > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2317 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 01-5-4 > Mar > 01 > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2318 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > Page 2319 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > System Information > System Diagnosis > P0703 > Page 2323 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > System Diagnosis > P1806 P1805 - P1809: Testing and Inspection P1806 For diagnosis of code P1806 refer to system experiencing problems Instrument Panel Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > System Diagnosis > P1806 > Page 2328 - For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Transfer Case B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > System Diagnosis > P1806 > Page 2329 P1805 - P1809: Testing and Inspection P1808 For diagnosis of code P1808 refer to system experiencing problems Instrument Panel Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > System Diagnosis > P1806 > Page 2330 - For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Transfer Case B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > Page 2331 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control REMOVAL NOTE: If equipped with power locks, perform steps one and eight. 1. Remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate window latch. For additional information, refer to Liftgate Latch. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 5. Disconnect the liftgate handle rod. 1 Open the clip. 2 Disconnect the liftgate handle rod. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > Page 2332 6. Disconnect the lock cylinder rod. 1 Open the clip. 2 Disconnect the lock cylinder rod. 7. Remove the liftgate latch remote control bolt. 8. Remove the liftgate latch remote control from the liftgate. INSTALLATION NOTE: If equipped with power locks, perform steps one and two. 1. Install the latch remote control and (if equipped) the push button rod into the liftgate. 2. Install the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 3. Loosely install the liftgate latch remote control bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > Page 2333 4. Install the liftgate window latch. 1 Position the liftgate window latch. 2 Install the nuts. 3 Connect the electrical connector. NOTE: Manually close the liftgate window latch to set the latch control rod length. 5. Connect the liftgate window latch actuating rod. 1 Position the liftgate window latch actuating rod. 2 Close the clip. 6. Tighten the liftgate latch remote control bolt. 7. Connect the lock cylinder rod. 1 Position the lock cylinder rod. 2 Close the clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > Page 2334 8. Connect the liftgate handle rod. 1 Position the liftgate handle rod. 2 Close the clip. NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 9. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not preloading the liftgate latch remote control. They should be clipped in a relaxed state with no slack. 10. Install the vent panel. 1 Position the vent panel. 2 Install the pin-type retainers. 11. Adjust the liftgate window latch. For additional information, refer to Liftgate Window Latch, Adjustment. See: Adjustments Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > System Information > Page 2335 12. Install the liftgate watershield. 13. Install the liftgate trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Specifications Trunk / Liftgate Latch: Specifications Liftgate Latch Bolt 9-14 Nm Liftgate Latch Remote Control 11-13 Nm Liftgate Window Latch Nuts 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Specifications > Page 2339 Liftgate Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Specifications > Page 2340 Trunk / Liftgate Latch: Adjustments 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Close the liftgate window glass. 4. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 5. Loosen the liftgate window latch nuts. 6. Adjust the liftgate window latch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Specifications > Page 2341 - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. 7. Tighten the liftgate window latch nuts. 8. Connect the liftgate window latch activating rod. 1 Connect the liftgate window latch actuating rod. 2 Lock the clip. 9. Verify the liftgate window glass flushness. 10. Install the liftgate watershield. 11. Install, the liftgate trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Disconnect the liftgate latch release rod from the liftgate latch remote control. 1 Open the clip. 2 Disconnect the liftgate latch release rod. 4. Remove the liftgate latch. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the liftgate latch and the liftgate release rod. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2344 1. To install, reverse the removal procedure. NOTE: If replacement of the liftgate latch release rods necessary, be sure to match the color coded rods for proper installation. - Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. - Position the liftgate latch release rod by pushing outboard to remove the slack. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2345 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control REMOVAL NOTE: If equipped with power locks, perform steps one and eight. 1. Remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate window latch. For additional information, refer to Liftgate Latch. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 5. Disconnect the liftgate handle rod. 1 Open the clip. 2 Disconnect the liftgate handle rod. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2346 6. Disconnect the lock cylinder rod. 1 Open the clip. 2 Disconnect the lock cylinder rod. 7. Remove the liftgate latch remote control bolt. 8. Remove the liftgate latch remote control from the liftgate. INSTALLATION NOTE: If equipped with power locks, perform steps one and two. 1. Install the latch remote control and (if equipped) the push button rod into the liftgate. 2. Install the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 3. Loosely install the liftgate latch remote control bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2347 4. Install the liftgate window latch. 1 Position the liftgate window latch. 2 Install the nuts. 3 Connect the electrical connector. NOTE: Manually close the liftgate window latch to set the latch control rod length. 5. Connect the liftgate window latch actuating rod. 1 Position the liftgate window latch actuating rod. 2 Close the clip. 6. Tighten the liftgate latch remote control bolt. 7. Connect the lock cylinder rod. 1 Position the lock cylinder rod. 2 Close the clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2348 8. Connect the liftgate handle rod. 1 Position the liftgate handle rod. 2 Close the clip. NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 9. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not preloading the liftgate latch remote control. They should be clipped in a relaxed state with no slack. 10. Install the vent panel. 1 Position the vent panel. 2 Install the pin-type retainers. 11. Adjust the liftgate window latch. For additional information, refer to Liftgate Window Latch, Adjustment. See: Adjustments Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2349 12. Install the liftgate watershield. 13. Install the liftgate trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2350 Trunk / Liftgate Latch: Service and Repair Liftgate window Latch REMOVAL 1. Open the liftgate window glass. 2. Remove the liftgate trim panel. 3. Remove the liftgate watershield. 4. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 5. Disconnect the electrical connector and remove the nuts. NOTE: Mark the position of the liftgate window latch prior to removing the nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Liftgate Latch > Page 2351 6. Remove the liftgate window latch. INSTALLATION 1. To install, reverse the removal procedure. Before installing the liftgate trim panel, adjust the liftgate window latch; refer to Liftgate Window Latch, Adjustment. See: Adjustments NOTE: Manually close the liftgate window latch to set the latch control rod length. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2359 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2360 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2366 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2367 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Impact Sensor: All Technical Service Bulletins Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2377 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2378 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2379 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2380 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 2381 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 2382 Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 2383 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Diagrams > 4R70W Transmission > Page 2386 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 2389 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 2390 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2400 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2401 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2402 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2403 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2404 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2407 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2408 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2409 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 2413 Neutral Safety Switch: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 2420 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2432 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2433 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2434 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2435 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2436 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2437 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2446 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2447 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2453 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 2454 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 2455 Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 2456 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission > Page 2459 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 2462 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 2463 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2469 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2470 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2471 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2472 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 2484 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermistor. It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 2489 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 2492 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 2495 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 2496 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch > Page 2502 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Four Wheel Drive Selector Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Description and Operation Rotary 4X4 Mode Switch 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch > Page 2521 Four Wheel Drive Selector Switch: Description and Operation Push Button 4X4 Mode Switch Switch, Push Button 4x4 Mode The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the instrument cluster push button, will illuminate only when the 4x4 Low position is engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Service and Repair Rotary 4X4 Mode Switch Mode Select Switch (MSS) Removal and Installation 1. Remove the Mode Select Switch (MSS) knob. 2. Remove the audio unit. 3. Remove the screws and pull the instrument panel center finish panel out of the instrument panel. 4. Disconnect the harness connector, remove the two screws and the MSS. 5. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 2524 Four Wheel Drive Selector Switch: Service and Repair Push Button 4X4 Mode Switch Removal and Installation 1. Remove and reposition the center instrument panel finish panel. 2. Disconnect the 4x4 mode switch electrical connector. 3. Remove the 4x4 mode switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 2525 4. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch 2 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 2535 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 2536 4 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 2537 Power Window Switch: Description and Operation The window regulator control switch: ^ Is located on each door trim panel. ^ May be used to raise or lower both LH side and RH side windows from the master control on the driver door. ^ Includes a window lock feature that is controlled through the master control. ^ Can manually lower the driver side window when the master control is depressed longer than 0.4 seconds. ^ The driver side window can be completely lowered when the master control is depressed between 0.04 and 0.4 seconds and then released. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2540 Terminals Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2541 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2542 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2543 Power Window Switch: Testing and Inspection Power window Switch Right Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2544 Schematic Left Rear Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2545 Terminals Schematic Right Rear Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2546 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2547 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door Power Window Switch: Service and Repair Driver Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. 3. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 4. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 2550 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 2551 Power Window Switch: Service and Repair Rear Door REMOVAL 1. Remove the rear window regulator switch plate. 1 Remove the screws. 2 Remove the rear window regulator switch plate. 2. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 3. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 2552 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Windshield Wiper Washer Switch 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 2557 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch Windshield Washer Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 2560 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2561 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2562 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2563 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2564 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2565 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2566 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2570 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 2573 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2574 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2575 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2576 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2577 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch Wiper Switch: Service and Repair Rear Wiper Switch REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the two screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 2580 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 2581 Wiper Switch: Service and Repair Multifunction Switch Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 2582 2 Remove the upper and lower steering column shrouds. 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 2588 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2589 Alignment: Specifications Caster LH 4.2 - 1.0 deg 0 deg. Frame Angle (If vehicle is higher in the rear, add the frame angle to the measured caster. If vehicle is lower in the rear, subtract the frame angle from the measured caster. Compare the total to the specification.) RH 4.2 - 1.0 deg Total/Split -0.7 +/- 0.5 deg Camber LH -0.5 +/- 0.5 deg RH -0.5 +/- 0.5 deg Total/Split 0 +/- 0.7 deg Toe 0.12 +/- 0.25 deg @ Curb Ride Height (positive value is toe-in, negative value is toe-out) Wheel Track 0.02 in Dogtracking 1.18 in maximum (centerline of front tires compared to centerline of rear tires) Clear Vision -2.4 +/- 3.0 deg (negative value is counterclockwise) Front Ride Height New Vehicles With less than 500 miles 4.4 +/- 0.4 in Original Parts 4.0 +/- 0.4 in Replacement Parts 4.4 +/- 0.1 in Rear Ride Height 4 Door Vehicles 5 - 5.8 in 2 Door Vehicles 4.3 - 4.8 in Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in Upper Ball Joint Maximum 1/32 in Vehicle Lean Front Wheel Opening Maximum 0.6 in Side to Side Height Differences Rear Wheel Opening Maximum 0.78 in Torque Specifications Caster Set Jam Nuts 129 ft lb Front Suspension Upper Arm Cam Nuts 98 ft lb Toe Set Jam Nuts 59 ft lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2592 Alignment: Description and Operation Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2593 Alignment: Description and Operation Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2594 Alignment: Description and Operation Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2595 Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Dogtracking Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2596 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). General Information Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Ride Height Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2597 Front Ride Height Measurement Rear Ride Height Measurement Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Toe Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2598 Positive Toe (Toe In) Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the farm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 4. To decrease the LF caster and camber, use the following steps. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2601 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2602 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2603 Alignment: Service and Repair Ride Height Ride Height - Front Suspension 1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to normalize the vehicle static ride height. 3. Measure the distance between the center line of the front suspension lower arm bushing bolt and the lift. Record the measurement. 4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the measurement. 5. Determine ride height. ^ Subtract measurement 1 from measurement 2. This is the ride height. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2604 6. Note: The torsion bar adjusting bolt is coated with adhesive that wears; off after disassembly. If the torsion bar system is ever disassembled or the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when re-assembling. Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting bolt. ^ Tighten the torsion bar adjusting bolt to increase the torque or raise the height. ^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height. Ride Height - Vehicle Dynamic Suspension Special Service Tool(s) 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid). ^ VENT (vent solenoid). 3. Close all doors including the liftgate and liftgate window. 4. Reopen any door (to ensure that the height will not change until the internal electronic calibration is complete). 5. Park the vehicle on a flat surface. 6. From the function menu, quickly select RIDE HEIGHT CALIBRATION. 7. Note the warning on the scan tool screen and follow the directions. 8. Lower the vehicle and clear all stored Diagnostic Trouble Codes (DTCs). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2605 Alignment: Service and Repair Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. Note: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod (3280) is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2606 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 750 RPM Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2622 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2623 Fuel Pressure Gauge Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2634 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. 1. Use the special tool to pull the spark plug wire off the spark plug with a twisting motion. 2. Squeeze the locking tab and twist while pulling upward to remove the spark plug wires from the ignition coils. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2635 1. Connect the spark plug wires to the ignition coils. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of spark plug and ignition coil boots of the spark plug wire. 2. Install the LH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2636 3. Install the RH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2641 Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2642 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. ............................................................. AWSF32EG LH Original Spark Plug Type ............................ ................................................................................................................................................... AWSF32E New Spark Plug Type (Either Side) ................................................................................... ................................................................................ AWSF32EE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2643 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2647 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2648 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2655 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2656 Drive Belt: Description and Operation The accessory drive system consists of the following: drive belt - generator - power steering pump - A/C compressor - crankshaft pulley - water pump pulley - drive belt tensioner - belt idler pulley The accessory drive: has a single serpentine drive belt (six ribs). - has an automatic tensioner. - is not adjustable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: 3. Inspect for drive belt cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms and go to the symptom chart. Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. - has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. The drive belt should be replaced if chunking occurs. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 5. If the concern(s) remains after inspection, determine the symptoms and go to the Symptom Chart. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2659 Drive Belt: Symptom Related Diagnostic Procedures 1 of 2 2 of 2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2660 Drive Belt: Component Tests and General Diagnostics Belt Tensioner The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can he checked by installing the suspect drive belt with a known good original equipment drive belt and repeating the observation. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Note: Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use. Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises. If the above procedures do not correct the drive belt noise, install a new drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as required. - Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2661 Drive Belt: Service and Repair Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the drive belt. 1 Rotate the drive belt tensioner clockwise. 2 Remove the drive belt. 3. Note: Refer to Component Locations for proper drive belt routing. See: Locations To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For additional information refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 2672 6. Disconnect the canister vent hose. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair. At this time, the torque converter, transmission cooler and tubes must be thoroughly flushed to remove any dirt. The transmission fluid needs to be changed if evidence of fluid contamination is found. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. 2. CAUTION: Use of a fluid other than specified could result in transmission failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level. Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 2676 7. Remove torque converter housing plug. 8. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler tubes. Installation 1. Note: A new torque converter drain plug must be used. Install the torque converter drain plug. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 2677 2. Install torque converter housing plug. 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. Note: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. Note: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 2678 6. Install bolts. 7. Lower the vehicle. 8. Note: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable. 9. Note: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(r) V. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2683 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2684 Fuel Pressure Gauge Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil bypass filter 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Hose clamps 8 - 11 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2700 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2701 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2707 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2708 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2709 Heater Hose: Specifications Water heater tube nut fitting 12 - 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2710 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Peanut Fitting Nut 7-9 Nm A/C Line To Condenser Nut 6.8-9.2 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2714 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2715 Spring Lock Coupling Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose to Power Steering Pump 48 ft.lb Power Steering Pump Bolts 18 ft.lb Steering Gear Pressure Fittings 22 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 2719 Power Steering Line/Hose: Service and Repair Special Tools Special Service Tool(s) Removal 1. Refer to the Description and Operation for the hose routing and retention points. Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 2724 Brake Fluid: Description and Operation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. ^ Do not mix different types of brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid Type DOT-3 Brake Fluid Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2732 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Fluid Capacity 14.9 L Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2735 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Refill Capacity ............................................................................................................... ..................................................................... 13.9 Qt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2740 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2741 Fluid - A/T: Service and Repair Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2742 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2743 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2744 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2749 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2750 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2753 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF CAUTION: Using a transmission fluid that indicates a dual usage MERCON and MERCON V in a transmission application requiring MERCON, may cause internal transmission damage. The use of any fluid other than the recommended fluid may cause transmission damage. Some fluid labels may indicate dual usage such as MERCON and MERCON V. These dual-usage fluids are not to be used in transmissions that use only the MERCON type fluid. These dual-usage fluids may be used in transmissions that require MERCON V use. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Axle ............................................................................................................................................ ..................................................................... 2.7 pints Rear Convetionial ........................................... .......................................................................................................................................................... 5.5 pints Rear Trac Lok ....................................................................................................................... ......................................................................................... 4 oz. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2758 Fluid - Differential: Fluid Type Specifications Front Differential Fluid Type Motorcraft SAE 80W90 XL-80W90-QL Thermally Stable 4x4 Axle Lubricant Specification ................ .............................................................................................................................................................. ................. WSP-M2C197-A Rear Differential Fluid Type Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A for 4.0L SOHC and 4.0L EI with a conventional differential. Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A for 4.0L SOHC and 4.0L EI with a limited slip differential and 5.0L. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks Fluid - Transfer Case: Customer Interest Front Axle - Vent Tube Fluid Leaks Article No. 01-8-6 4/30/01 ^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD ^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 EXPLORER 1997-2001 RANGER MERCURY: 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model applications and model years. ISSUE Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the Instruction Sheet included in the kit and the following text for details. The Cover Kit (F6TZ-4033-BA) includes the following: ^ One (1) Cover One (1) Hose ^ One (1) Hose Connector One (1) Vent Plug One (1) Clip ^ One (1) Sealant ^ One (1) Instruction Sheet NOTE SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 010806A Install Axle Cover kit 1.7 Hrs. DEALER CODING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks > Page 2767 CONDITION BASIC PART NO. CODE 4022 D1 OASIS CODES: 509000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks Fluid - Transfer Case: All Technical Service Bulletins Front Axle - Vent Tube Fluid Leaks Article No. 01-8-6 4/30/01 ^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD ^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 EXPLORER 1997-2001 RANGER MERCURY: 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model applications and model years. ISSUE Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the Instruction Sheet included in the kit and the following text for details. The Cover Kit (F6TZ-4033-BA) includes the following: ^ One (1) Cover One (1) Hose ^ One (1) Hose Connector One (1) Vent Plug One (1) Clip ^ One (1) Sealant ^ One (1) Instruction Sheet NOTE SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 010806A Install Axle Cover kit 1.7 Hrs. DEALER CODING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks > Page 2773 CONDITION BASIC PART NO. CODE 4022 D1 OASIS CODES: 509000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... ...................................................................... 3.0 Pints Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2776 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2781 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2782 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2783 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2786 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................... SAE 5W-20 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2787 Engine Oil: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2792 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2793 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2798 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2799 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2800 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2801 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications System Capacity 30 oz (US) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2804 Refrigerant: Fluid Type Specifications R-134a Refrigerant Ford Part Number................................................................................................................................. ...................................................Motorcraft YN-19 Ford Specification................................................................................................................................. ....................................................WSH-M17B19-A Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2805 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2806 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2807 Refrigerant: Service and Repair SPECIAL SERVICE TOOL(S) 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing. See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics/Identifying Refrigerants 2. Connect the R-134a A/C refrigerant center to the low and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. For additional information, refer to Manifold Gauge Set Connection. See: Heating and Air Conditioning/Service and Repair/Manifold Gauge Set Connection 3. Perform the Refrigerant Discharging and Recovery Procedure. 4. Once the refrigerant center has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 6. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs, then Perform the Evacuation and Charging Procedure. For additional information, refer to Evacuation and Charging. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications System Capacity 9 oz (US) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2812 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) Ford Part Number................................................................................................................................. ................F7AZ-19589-DA (Motorcraft YN-12-C) Ford Specification................................................................................................................................. ...................................................WSH-M1C231-B Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2813 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. - Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2814 4. For the A/C condenser core , add 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice. - installation of a new A/C compressor pressure relief valve. - installation of a new refrigerant line. - repair of an O-ring seal leak. - repair of a charge port leak. 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Caliper bleeder screw, rear 15 ft.lb Caliper bleeder screw, front 15 ft.lb Master cylinder bleeder screw 70-159 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2820 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2821 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2822 Brake Bleeding: Service and Repair Brake System Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2823 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed procedure as outlined in Steps 3 - 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2824 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been installed new or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2825 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, remove the cruise switch. 5. Fill the cruise switch with the specified brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2826 6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles are seen in the expelled brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2827 14. Repeat the above four steps for the remaining master cylinder outlet tube. 15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 16. Have an assistant pump and then hold firm pressure on the brake pedal. 17. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 20. Bleed the brake system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 2828 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2833 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2834 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2835 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2836 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2837 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2838 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2844 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2845 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2846 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2847 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2848 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2849 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2850 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2851 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2852 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2853 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2854 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2855 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2874 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2875 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2876 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2877 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2878 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2879 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2880 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2881 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2882 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2883 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2884 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2885 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2890 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2891 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2892 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2893 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2894 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2895 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2896 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2897 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2898 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2899 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2900 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2901 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2916 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2917 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2920 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2921 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2922 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2923 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2924 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2925 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2926 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2927 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2928 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2929 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2934 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2935 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2936 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2937 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2938 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2939 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2940 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2941 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2942 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2943 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2944 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2945 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2948 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2949 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2950 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2951 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2954 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2955 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2956 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2957 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2958 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2959 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2960 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2961 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2962 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2963 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2964 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2965 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 2970 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. - When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: - oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 2974 Oil Change Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 2975 Oil Change Reminder Lamp: Service and Repair Oil Change Reset Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of 12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL CHANGE RESET control for five seconds. The message center will count down for five seconds. After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have established a personalized oil reset percentage, the display will show that percentage instead of 100%.) This reset procedure should be performed only after an oil change to ensure accurate oil life indications. Your personalized oil reset percentage allows you to establish a smaller oil change interval than the manufacturer's recommended interval. To establish your personalized oil reset percentage: 1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display is still counting gown the five seconds to reset. The display will change to START OIL LIFE AT XXX%. 2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil reset percentage you desire. Your choices are 100%, 90%, 80%, 70%, 60%, 50% 40% and 30%. 3. Press the RESET control to complete the procedure. Pressing any control other than RESET of OIL CHANGE RESET will abort this procedure and will not establish your new personalized oil reset percentage. When your personalized oil reset percentage has been established, it will be used beginning with the completion of your next OIL CHANGE RESET procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear axle tube. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2983 Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2992 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2993 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2994 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2995 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2996 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2997 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2998 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2999 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3000 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3001 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3006 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3007 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3008 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3009 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3010 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3011 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3012 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3017 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3018 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3019 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3020 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3021 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3022 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3023 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3029 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3030 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3031 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3037 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3038 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3039 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 3044 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3049 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3050 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3051 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3052 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3053 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3054 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3055 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3056 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3057 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3058 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3063 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3064 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3065 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3066 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3067 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3068 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3069 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3074 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3075 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3076 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3077 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3078 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3079 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3080 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3086 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3087 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3088 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 3093 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 3099 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3104 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3105 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3106 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3107 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3108 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3109 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3110 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3111 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3112 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3113 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3118 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3119 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3120 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3121 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3122 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3123 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3124 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3129 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3130 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3131 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3132 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3133 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3134 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 3135 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 3136 Tires: Specifications Tire Tread Depth P225/70R15 A/S 0.37 in P235/75R15 A/T 0.42 in P255/70R16 A/T 0.42 in Maximum Radial Runount Aluminum 0.040 in Steel 0.040 in Maximum Lateral Runout Aluminum 0.040 in Steel 0.040 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 3137 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 3138 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 3143 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 3144 Wheels: Specifications Maximum Radial Runount Aluminum 0.045 in Steel 0.045 in Maximum Lateral Runout Aluminum 0.045 in Steel 0.045 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 3145 Wheels: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 3148 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 3149 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 3155 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 3156 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Special Service Tool(s) Removal 1. Remove the brake disc. 2. Remove the three bolts and the dust shield. 3. CAUTION: Discard the wheel hub retainer nut and washer assembly. It is a torque prevailing design and cannot be reused. Remove the wheel hub retainer nut and washer assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 3159 4. Remove the front brake anti-lock sensor. 1 Remove the bolt. 2 Remove the front brake anti-lock sensor. 5. CAUTION: Do not overextend CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the three bolts and the wheel hub. 6. Remove the seal. Installation 1. Install the seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 3160 ^ Using the Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer, install the seal. 2. Install the wheel hub. ^ Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. Install the three bolts. 3. Install the dust shield. 4. Install the front brake anti-lock sensor. 1 Position the front brake anti-lock sensor. 2 Install the bolt. 5. Install the wheel hub retainer nut and washer assembly. 6. Install the brake disc. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 3161 Wheel Bearing: Service and Repair Rear Special Tools Special Tools Removal 1. Remove the axle shaft. See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 3162 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Hub Nut 157-213 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts 100 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the brake disc and hub. 4. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 3172 Wheel Fastener: Service and Repair Rear Special Tool(s) Special Service Tool(s) Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which can result in shifting of the vehicle curing these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support the rear disc brake caliper with safety wire. 5. Using the C-Frame and Clamp Assembly Tool, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 3173 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. 2. Seat new wheel studs in axle flange. - Place four flat washers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flat washers. 4. Install the brake disc, rear disc support bracket the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Turn the air suspension service switch on, if so equipped. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear axle tube. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 3177 Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3183 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3184 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Service and Repair Camshaft Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt 40 - 45 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket > Page 3193 Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt 40-45 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Camshaft thrust plate bolt 9 - 12 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Intake lobe lift 0.2637 in Exhaust lobe lift 0.2801 in Maximum allowable lobe lift loss 0.005 in End play 0.001 - 0.007 in End play wear limit 0.009 in Journal to bearing clearance 0.001 - 0.003 in Service limit 0.006 in No.1 journal diameter 2.0815 in No.2 Journal diameter 2.0665 in No.3 journal diameter 2.0515 in No.4 journal diameter 2.0365 in No.5 journal diameter 2.0215 in Maximum camshaft journal runout 0.005 in No.1 bearing inside diameter 2.0835 in No.2 bearing inside diameter 2.0685 in No.3 bearing inside diameter 2.0535 in No.4 bearing inside diameter 2.0385 in No.5 bearing inside diameter 2.0235 in Front bearing location depth 0.005 - 0.020 in. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3200 Camshaft: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Tappet diameter 0.8740 - 0.8745 in Tappet to bore clearance 0.0007 - 0.0027 in Service limit 0.005 in Hydraulic lifter Leakdown rate for 1/16 in travel 10 - 50 sec Collapsed tappet gap allowable 0.071 - 0.171 in Collapsed tappet gap desired 0.091 - 0.151 in Valve tappet guide plate retainer bolts 71-106 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 3204 Lifter / Lash Adjuster: Service and Repair Removal 1. Remove the lower intake manifold. 2. Remove the valve covers. 3. Remove the bolts. Note: Make sure to mark the rocker arms and the push rods so they will be installed in their original positions. 4. Remove the eight rocker arm seats. 5. Remove the eight rocker arms and rocker arm fulcrum guides. 6. Remove the eight push rods and mark them so they can be reinstalled in their original positions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 3205 7. Remove the bolts and remove the valve tappet guide plate retainer. 8. Note: Mark the valve tappets so they can be reinstalled in their original positions. Remove the four valve tappet guides and the valve tappets using a valve tappet puller. 9. Inspect the valve tappets. Installation 1. Lubricate the valve tappet bores before installing the valve tappets. - Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Install the valve tappets and the valve tappet guide plates in their original positions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 3206 3. Position the valve tappet guide plate retainer and install the bolts. 4. Install the push rods in the original location. 5. Apply engine oil to the top of the valve stem, rocker arm seats, and rocker arms. - Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 6. Install the eight rocker arms and rocker arm fulcrum guides. 7. Install the eight rocker arm seats. 8. Install the bolts. 9. Check the valve clearance. 10. Install the valve cover on the side that is being repaired. 11. Install the lower intake manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Maximum valve rocker arm lift ratio to 1 0.062 Rocker arm bolts 18 - 25 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair Connecting Rod Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Bearings Clearance to crankshaft - desired 0.0008 - 0.0015 in Clearance to crankshaft - allowable 0.0007 - 0.0024 in Bearing wall thickness (STD) 0.0572 - 0.0577 in Main Bearings Clearance to crankshaft - desired 0.0008 - 0.00015 in Clearance to Crankshaft - allowable 0.0008 - 0.003 in Bearing wall thickness (STD) 0.0957 - 0.0960 in Piston pin bore or bushing I.D. 0.909 - 0.911 in Rod bearing bore I.D. 2.2390 - 2.2393 in Rod bearing bore out-of-round 0.0004 in Rod length center to center 5.0885 - 5.0915 in Alignment (bore-to-bore max. Diff.) twist 0.015 in Service limit 0.023 in Alignment (bore-to-bore max. Miff.) bend 0.012 in Side clearance (assembled to crank) 0.010 - 0.020 in Connecting rod cap nuts 19-24 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 3217 Connecting Rod: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main Bearings - Clearance to Crankshaft (Desired) 0.0008-0.0015 in Main Bearings - Clearance to Crankshaft (Allowable) 0.0007-0.0024 in Bearing Wall Thickness (STD.) 0.0572-0.0577 in Main Bearing Cap Bolts 61-68 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 3221 Crankshaft Main Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main bearing journal diameter 2.2482 - 2.2490 in Main bearing journal out-of-round 0.0006 in Main bearing journal runout TIR maximum 0.002 in Main bearing journal runout service limit 0.005 in Main bearing thrust face runout TIR maximum 0.001 in Main bearing journal taper maximum per inch 0.0005 in Thrust bearing journal length 1.137 - 1.139 km Main and rod bearing journal finish RMS maximum 12 Main bearing thrust face finish RMS maximum Front 25 Rear 20 Connecting rod journal diameter 2.1228 - 2.1236 in Connecting rod journal maximum out-of-round 0.0006 in Connecting rod journal taper per inch maximum 0.0006 in Crankshaft free end play 0.004 - 0.008 in Crankshaft free end play service limit 0.005 in Crankshaft main bearing cap bolts 61-68 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3225 Crankshaft: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Block heater screw 14 - 16 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 3229 Engine Block Heater: Service and Repair Removal 1. Drain the cooling system. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Remove the block heater. 1 Note: Do not loosen the screw more than necessary for removal. Loosen the screw. 2 Twist and slide the block heater to release the retainer clip and discard the retainer clip. 3 Remove the block heater. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Pulley, Crankshaft Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft vibration damper bolt 110 - 130 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Pulley, Crankshaft > Page 3234 Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft vibration damper bolt 110 - 130 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3235 Harmonic Balancer - Crankshaft Pulley: Service and Repair Special Tools Removal and Installation 1. Remove the fan shroud. 2. Remove the accessory drive belt. 3. Note: Use a suitable strap wrench to hold the crankshaft pulley. Remove the bolt. 4. Note: The jackscrew from Damper Puller Adapter must be used with Crankshaft Damper Remover. Use Crankshaft Damper Remover to remove the crankshaft pulley. 1 Install the Crankshaft Damper Remover. 2 Remove the crankshaft pulley. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3236 5. Apply silicone sealant to the woodruff key slot on the crankshaft pulley. - Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 6. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Diameter-coded red 3.9987 - 3.9993 in Diameter-coded blue 3.9999 - 4.0005 in Diameter-coded yellow 4.0011 - 4.0017 in Bore clearance selective fit 0.0012 - 0.0020 in Pin bore diameter 0.9126 - 0.9128 in Top ring grove width 0.060 - 0.061 in Bottom ring grove width 0.060 - 0.061 in Oil ring grove width 0.1587 - 0.1597 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 3240 Piston: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Length 3.010 - 3.040 in Diameter 0.9121 - 0.9122 in To piston pin bore clearance 0.0004 - 0.0007 in To connecting rod bushing clearance Interference Fit Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 3244 Piston Pin: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Top compression ring width 0.0577 - 0.0587 in Bottom compression ring width 0.0577 - 0.0587 in Top compression side clearance 0.0013 - 0.0033 in Bottom compression side clearance 0.0013 - 0.0033 in Oil ring side clearances Snug Top compression ring gap 0.010 - 0.020 in Bottom compression ring gap 0.018 - 0.028 in Oil ring gap 0.010 - 0.040 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 3248 Piston Ring: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 3256 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 3257 Fuel Pressure Gauge Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Maximum valve rocker arm lift ratio to 1 0.062 Rocker arm bolts 18 - 25 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications LH Valve Cover Bolts (in Sequence) 12 - 15 ft.lb RH Valve Cover Bolts (in Sequence) 12 - 15 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH Valve Cover: Service and Repair LH Removal 1. Remove the upper intake manifold. 2. Disconnect the fuel line. 3. Disconnect the fuel line from the LH valve cover and position aside. 4. Disconnect the spark plug wires from the LH valve cover. 5. Remove the bolts and LH valve cover. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3266 1. Note: Make sure the stamping and chamfered edges of the steel carrier in the new LH valve cover gasket are facing up. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3267 Valve Cover: Service and Repair RH Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube. 3. Disconnect the idle air control (IAC) valve electrical connector. 4. Remove the bolt and the accelerator control snow shield. 5. Disconnect the accelerator and speed control (if equipped) cables from the throttle linkage. 6. Remove the accelerator cable bracket nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3268 7. Remove the accelerator cable bracket lower nut. 8. Remove the accelerator and speed control (if equipped) cables from the clip. 9. Remove the accelerator cable bracket. 1 Remove the nut. 2 Remove the accelerator cable bracket. 10. Disconnect the throttle position (TP) sensor electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3269 11. Remove the EGR vacuum connector. 12. Disconnect the two pressure transducer hoses. 13. Disconnect the lower EGR valve-to-exhaust manifold tube fitting. 14. Disconnect the upper EGR valve-to-exhaust manifold tube fitting and remove the EGR valve to exhaust manifold tube. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3270 15. Note: Rear EGR spacer studs must be removed prior to EGR spacer removal. Use two nuts tightened against one another to remove the studs. Remove the EGR spacer bolts, nuts and the EGR spacer. 16. Disconnect the RH number 4 spark plug wire. 17. Remove the bolts and the RH valve cover. Installation 1. Note: Make sure stamping and chamfered edges of the steel carrier in the new RH valve cover gasket are facing up. Install RH valve cover. 2. CAUTION: Clean the EGR spacer and throttle body gasket surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A and a Teflon (R) or hardwood scraper. Avoid the use of metal scraper or abrasive materials when removing old gasket material, or possible vacuum and EGR passage leaks may result. On early models, install the EGR spacer gasket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3271 3. Install the EGR spacer, bolts, and the nuts. 4. Connect the lower EGR valve-to-exhaust manifold tube nut. 5. Connect the upper EGR valve-to-exhaust manifold tube nut. 6. Connect the two EGR pressure transducer hoses. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3272 7. Connect the EGR valve vacuum connector. 8. Connect the throttle position (TP) sensor electrical connector. 9. Install the accelerator cable bracket. 1 Position the accelerator cable bracket. 2 Install the bolt. 10. Install the accelerator cable bracket lower nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3273 11. Install the accelerator cable bracket nut. 12. Connect the accelerator and speed control (if equipped) cables to the throttle linkage. 13. Position the accelerator and speed control (if equipped) cables into the clip. 14. Install the accelerator control splash shield. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 3274 15. Connect the idle air control (IAC) valve electrical connector. 16. Connect the PCV hose to the throttle body. 17. Install the air cleaner outlet tube. 18. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Width 0.060 - 0.080 in Angle degrees 45 deg Runout TIR maximum 0.002 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Intake valve spring free length 2.06 in Exhaust valve spring free length 1.89 in Intake valve spring assembled height 1.75 - 1.81 in Exhaust valve spring assembled height 1.58 - 1.64 in Valve spring out of square 0.078 in Spring compression pressure at specified height (lbs.) Intake valve 190-210 at 1.20 74-82 at 1.78 Exhaust valve 190-210 at 1.20 76-84 at 1.60 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 3281 Valve Spring: Service and Repair Removal 1. Remove the rocker arm of the valve to be repaired. 2. Position the piston at top dead center (TDC). 3. Remove the spark plugs. 4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. Install compressed air in the cylinder to hold both valves in position. 5. Use a suitable valve spring compressor, remove the valve spring retainer key. Note: Mark the location of the parts so they can be installed in their original positions. 6. Remove the valve springs. 1 Remove the valve spring rotator (exhaust). 2 Remove the valve spring retainer sleeve (intake). 3 Remove the valve spring retainer (intake). 4 Remove the valve springs. 7. Check the valves and valve springs. Installation 1. Lubricate the valve stem. - Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 3282 2. Install the valve springs. 1 Install the valve springs. 2 Install the valve spring retainer (intake). 3 Install the valve spring retainer sleeve (intake). 4 Install the valve spring rotator (exhaust). 3. Use a suitable valve spring compressor install the valve spring retainer keys. 4. Remove the compressed air line. 5. Install the spark plugs. 6. Install the rocker arm. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve stem diameter standard Intake 0.3415 - 0.3423 mm Exhaust 0.3410 - 0.3418 mm Valve stem diameter 0.0l5 oversize Intake 0.3565 - 0.3573 mm Exhaust 0.3561 - 0.3568 mm Valve stem diameter 0.030 oversize Intake 0.3715 - 0.3723 mm Exhaust 0.3711 - 0.3718 mm Valve stem to guide clearance intake 0.0010 - 0.0027 in Valve stem to guide clearance exhaust 0.0055 - 0.0032 in Service limit 0.0055 in Head diameter intake 1.837 - 1.847 in Head diameter exhaust 1.536 - 1.546 in Valve face angle degrees 44 deg Valve face runout limit 0.002 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 3286 Valve: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 3291 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 3292 Drive Belt: Description and Operation The accessory drive system consists of the following: drive belt - generator - power steering pump - A/C compressor - crankshaft pulley - water pump pulley - drive belt tensioner - belt idler pulley The accessory drive: has a single serpentine drive belt (six ribs). - has an automatic tensioner. - is not adjustable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: 3. Inspect for drive belt cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms and go to the symptom chart. Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. - has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. The drive belt should be replaced if chunking occurs. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 5. If the concern(s) remains after inspection, determine the symptoms and go to the Symptom Chart. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3295 Drive Belt: Symptom Related Diagnostic Procedures 1 of 2 2 of 2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3296 Drive Belt: Component Tests and General Diagnostics Belt Tensioner The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can he checked by installing the suspect drive belt with a known good original equipment drive belt and repeating the observation. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Note: Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use. Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises. If the above procedures do not correct the drive belt noise, install a new drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as required. - Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3297 Drive Belt: Service and Repair Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the drive belt. 1 Rotate the drive belt tensioner clockwise. 2 Remove the drive belt. 3. Note: Refer to Component Locations for proper drive belt routing. See: Locations To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive belt tensioner bolts 16 - 21 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 3301 Drive Belt Tensioner: Service and Repair Removal and Installation 1. Remove the drive belt. 2. Remove the drive belt tensioner. 3. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine mount nuts 109 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 3305 Engine Mount: Service and Repair WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and Support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. Move the vehicle in forward and reverse (2 - 4 ft). CAUTION: Do not twist or strain the powertrain/drivetrain mounts. 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Belt idler pulley bolt (upper) 35 ft.lb Belt idler pulley bolt (lower) 16 - 21 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 3309 Idler Pulley: Service and Repair Belt Idler Pulley-5.0L, Lower Removal and Installation 1. Remove the drive bolt. 2. Remove the belt idler pulley. 3. To install, reverse the removal procedure. Belt Idler Pulley-5.0L, Upper Removal and Installation 1. Remove the drive belt. 2. Remove the belt idler pulley. 3. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure at 2000 RPM Hot 40-60 psi Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil level indicator tube nut 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3321 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3322 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3323 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3326 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................... SAE 5W-20 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3327 Engine Oil: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications Oil cooler bolt 39 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil bypass filter 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan side bolts 11 ft.lb Oil pan end bolts 15 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations > Page 3343 Oil Pressure Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 12-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 3347 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 3348 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 3349 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil pump screen cover and tube bolts 12 - 18 ft.lb Oil pump screen cover and tube nut 23 - 31 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure at 2000 RPM Hot 40-60 psi Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Lower Intake Manifold Bolts (in Sequence) Step 1 89 in.lb Step 2 24 ft.lb Fuel Injection Supply Manifold Bolts 71-106 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold: Service and Repair Lower Removal 1. Drain the engine cooling system. 2. Disconnect the radiator overflow hose and position aside. 3. Remove the upper intake manifold. 4. Disconnect the water bypass hose from the water heater tube. 5. Disconnect the engine coolant temperature (ECT) electrical connector. 6. Remove the wire harness retainer nut. 7. Disconnect the heater water hoses. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3362 8. Disconnect the two PCV heater hoses from the water heater tube 9. Disconnect the upper radiator hose. 10. Remove the water bypass hose. 1 Loosen the water bypass hose clamps. 2 Remove the water bypass hose. 11. Disconnect the eight fuel injector electrical connectors. 12. Disconnect the fuel line. 13. Disconnect the ground strap at the rear of the lower intake manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3363 14. Disconnect the water temperature indicator sender electrical connector. 15. Remove the camshaft position (CMP) sensor and the camshaft synchronizer. 16. Remove the bolts. 17. Remove the lower intake manifold and discard the lower gasket. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3364 1. Note: Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean the gasket surfaces of the lower intake manifold, cylinder heads, and the cylinder block. Apply a 1.6 mm (0.06) bead of sealer in the corners where the cylinder head and cylinder block meet. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 2. Position the four lower gaskets. - Install the intake manifold seal tabs to notch in the lower intake manifold gaskets. - Press firmly along the entire length of the intake manifold seal until silicone sealant is visible. 3. Position the lower intake manifold and start the bolts. 4. Tighten the lower intake manifold in two steps. - Step 1: Tighten to 10 Nm (89 inch lbs.). - Step 2: Tighten to 32 Nm (24 ft. lbs.). 5. Install the camshaft position (CMP) sensor and the camshaft synchronizer. 6. Connect the rear ground strap to the rear of the lower intake manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3365 7. Connect the water temperature indicator sender electrical connector. 8. Connect the eight fuel injector electrical connectors. 9. Reconnect the fuel line. 10. Install the water bypass hose. 1 Position the water bypass hose. 2 Install the two clamps. 11. Connect the upper radiator hose. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3366 12. Connect the heater water hoses. 13. Install the wire harness retainer nut. 14. Connect the engine coolant temperature (ECT) electrical connector. 15. Connect the water heater bypass hose to the heater tube. 16. Connect the two PCV heater hoses to the heater tube. 17. Install the upper intake manifold. 18. Connect the radiator overflow hose. 19. Fill the engine cooling system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3367 Intake Manifold: Service and Repair Upper Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube. 3. Disconnect the idle air control (IAC) electrical connector. 4. Remove the bolt and the accelerator control splash shield. 5. Disconnect the throttle position (TP) sensor electrical connector. 6. Disconnect the accelerator and speed control (if equipped) cables from the throttle linkage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3368 7. Remove the accelerator cable bracket nut. 8. Remove the lower accelerator cable bracket nut. 9. Remove the accelerator and speed control (if equipped) cables from the clip. 10. Remove the accelerator cable bracket. 1 Remove the nut. 2 Remove the accelerator cable bracket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3369 11. Disconnect the EGR valve vacuum connector. 12. Disconnect the fuel pressure regulator vacuum connection. 13. Disconnect the two pressure transducer hoses. 14. Disconnect the upper EGR valve-to-exhaust manifold tube fitting. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3370 15. Disconnect the following connections: - Engine vacuum regulator (EVR) electrical connector - EVR vacuum connector 16. Disconnect the EGR backpressure transducer electrical connector. 17. Remove the ignition coil bracket. 18. Disconnect the accelerator cable from the upper intake manifold clips. 19. Remove the screws and the intake cover plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3371 20. Remove the bolts in the sequence shown. 21. Disconnect the two vacuum connections from the front of the intake manifold. 22. Disconnect the vapor management valve (VMV) purge line. 23. Disconnect the brake booster vacuum supply line at the LH rear upper intake connection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3372 24. Disconnect the positive crankcase ventilation (PCV) hose, and the two PCV heater hoses. 25. Remove the upper intake manifold and discard the old gasket. Installation 1. Note: Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A and a suitable plastic or wooden scraper to clean the upper and lower intake manifold gasket surfaces. Clean and inspect all surfaces, install new seals and gaskets. 2. Position the upper intake manifold and gasket and start the bolts. 3. Connect the two upper intake vacuum connections. 4. Connect the positive crankcase ventilation (PCV) tube, and the two PCV heater hoses. 5. Connect the vacuum supply line to the brake booster at the LH rear upper intake connection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3373 6. Tighten the bolts in the sequence shown. 7. Install the upper intake manifold cover plate and tighten the screws. 8. Install the accelerator cable bracket. 1 Position the accelerator cable bracket. 2 Install the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3374 9. Install the lower accelerator cable bracket nut. 10. Install the accelerator cable bracket nut. 11. Connect the accelerator and speed control (if equipped) cables to the throttle linkage. 12. Position the accelerator and speed control (if equipped) cables into the clip. 13. Install the ignition coils and the ignition coil bracket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3375 14. Connect the following connections: - Engine vacuum regulator (EVR) electrical connector - EVR vacuum connector 15. Connect the EGR valve vacuum connector. 16. Connect the fuel pressure regulator vacuum connector. 17. Connect the upper EGR valve-to-exhaust manifold tube connection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3376 18. Connect the EGR backpressure transducer electrical connection. 19. Connect the TP sensor electrical connector. 20. Connect the IAC electrical connector. 21. Install the accelerator control splash shield. 22. Install the air cleaner outlet tube. 23. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations > Page 3384 Oil Pressure Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Special Tools Removal 1. Remove the flywheel. 2. CAUTION: Avoid scratching or damaging the oil seal surfaces during removal of the crankshaft rear oil seal. Note: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use extra-fine emery cloth or extra-fine 0000 steel wool with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. Use Rear Crankshaft Seal Remover and Impact Slide Hammer to remove the crankshaft rear main seal. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3389 1. Lubricate the and crankshaft sealing surface. - Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Position Rear Crank Adapter and use Rear Crank Seal Replacer Spacer and Rear Crank Seal Replacer to install the crankshaft rear oil seal. 3. Check that the crankshaft rear oil seal is within specification. 4. Install the flywheel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3394 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3395 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3396 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3397 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3398 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3399 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Special Tools Removal 1. Remove the crankshaft pulley. 2. Use the special tool to remove the crankshaft front seal. Installation 1. Install the crankshaft front seal using the special tool. 2. Install the crankshaft pulley. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Special Tools Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. Use the special tool to install the valve stem seals. 2. Install the valve shrines. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 12-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 3410 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 3411 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 3412 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt 40 - 45 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket > Page 3418 Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt 40-45 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams Timing Chain: Diagrams Position the crankshaft sprocket, the camshaft sprocket, and the timing chain while aligning the timing marks. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 750 RPM Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3437 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3438 Fuel Pressure Gauge Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3449 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. 1. Use the special tool to pull the spark plug wire off the spark plug with a twisting motion. 2. Squeeze the locking tab and twist while pulling upward to remove the spark plug wires from the ignition coils. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3450 1. Connect the spark plug wires to the ignition coils. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of spark plug and ignition coil boots of the spark plug wire. 2. Install the LH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3451 3. Install the RH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3456 Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3457 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. ............................................................. AWSF32EG LH Original Spark Plug Type ............................ ................................................................................................................................................... AWSF32E New Spark Plug Type (Either Side) ................................................................................... ................................................................................ AWSF32EE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3458 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3462 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3463 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 15 - 21 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump > Page 3471 Water Pump: Specifications Water pump pulley bolts 12 - 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3472 Water Pump: Service and Repair Removal 1. Remove the fan shroud. 2. Drain the cooling system. 3. Remove the accessory drive belt. 1 Turn the tensioner pulley clockwise. 2 Remove the accessory drive belt. 4. Remove the water bypass hose. 1 Loosen the water bypass hose clamps. 2 Remove the water bypass tube. 5. Loosen the water heater hose clamp and disconnect the water heater hose from the water pump. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3473 6. Remove the two retaining nuts and position the engine control sensor wiring aside. 7. Remove the bolts and the water pump pulley. 8. Remove the bolts and remove the water pump from the engine front cover. 9. Loosen the water pump inlet hose clamp and remove the water pump. Installation 1. Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A and a suitable plastic or wooden scraper to clean the gasket surfaces of the engine from cover and water pump. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3474 2. Install the water pump inlet hose on the water pump. 3. Position the water pump and install the bolts. 4. Position the engine control sensor wiring, and install the two nuts. 5. Install the water pump pulley. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3475 6. Install the water heater hose and clamp. 7. Install the water bypass tube. 1 Position the water bypass tube. 2 Install the two water bypass hose clamps. 8. Position the accessory drive belt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3476 9. Install the accessory drive belt. 1 Turn the tensioner clockwise. 2 Install the belt. 10. Install the fan shroud. 11. Fill the cooling system. 12. Start the engine and check for leaks. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 3482 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Fluid Capacity 14.9 L Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3485 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Hose clamps 8 - 11 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Radiator Coolant Recovery Reservoir Bolts ....................................................................................................................................... 6-8 Nm (53-71 in.lb.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3492 Coolant Reservoir: Service and Repair Removal 1. Remove the air cleaner outlet tube and the engine air cleaner (ACL). 2. Remove the bolt and position the speed control servo aside. 3. Disconnect the windshield washer hose from under the dash panel and plug the end of the hose. 4. Disconnect the windshield washer pump electrical connector from the windshield washer reservoir. 5. Position the (A) clamp back and disconnect the (B) radiator overflow hose from the (C) radiator filler neck and plug the hose. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3493 6. Remove the (A) two nuts and the (B) bolts. 7. Remove the radiator coolant recovery reservoir and the windshield washer reservoir. Installation 1. Install the radiator coolant recovery reservoir and the windshield washer reservoir. 2. Install the bolts and the two nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3494 3. Connect the (B) radiator overflow hose to the (C) radiator filler neck and position the (A) clamp. 4. Connect the windshield washer pump electrical connector to the windshield washer reservoir. 5. Connect the windshield washer hose under the dash panel. 6. Position the speed control servo and bracket and install the bolt. 7. Fill the cooling system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Removal and Installation 1. Remove fan shroud. 2. Remove the bolts. 3. Separate the fan blade from the fan clutch. 4. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications Fan clutch bolts 14 - 19 ft.lb Fan clutch to water pump pulley nut 34 - 46 ft.lb Fan blade to fan clutch bolts 53 - 71 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3502 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3507 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3508 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3511 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 3512 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Partially drain the cooling system. For additional information, refer to Cooling System. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 8-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3516 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan shroud bolts 53 - 71 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3520 Fan Shroud: Service and Repair Special Tools Removal and Installation 1. Remove the air cleaner outlet tube. 2. Use the Fan Clutch Wrench and the Fan Hub Wrench to loosen and remove the fan blade. 3. Remove the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3521 4. Lift the fan shroud out of the lower retaining clips. 5. Lift the fan shroud and the fan blade and clutch assembly together and remove from the vehicle. 6. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3530 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3531 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3537 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3538 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3539 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3540 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3541 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3542 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE IN LET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot. the heater core may have an air pocket - the heater core may be plugged - the thermostat is not working correctly. Heater Core-Pressure Test Use Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. For additional information, refer to Cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3543 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3544 Heater Core: Service and Repair REMOVAL 1. Drain the radiator. NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 2. Remove the heater water hoses. 1 Squeeze the clamps and pull the hoses off. 2 Disconnect the vacuum hose from the water control valve. 3. Remove the A/C evaporator core housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Heating and Air Conditioning/Evaporator Case/Service and Repair 4. Remove the dash board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Remove the Powertrain Control Module (PCM), please refer to Powertrain Management/Computers and Control Systems/Engine Control Module/Service and Repair/ See: Powertrain Management/Computers and Control Systems/Powertrain Control Module/Service and Repair/Procedures 6. Remove the PCM heat sink. 1 Remove the ground strap screw. 2 Remove the heat sink. 7. Remove the heater air plenum nuts from the engine side of the dash panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3545 8. Remove the heater core. 1 Remove the heater core cover to air plenum screws. 2 Lift off the cover. 9. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Be sure to install a new oval foam seal around the heater core inlet and outlet tubes. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3554 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3555 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3561 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3562 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3563 Heater Hose: Specifications Water heater tube nut fitting 12 - 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3564 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations > Page 3569 Temperature Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. 1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C104, circuit 39 (RD/WH), and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid range. Key OFF. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations > Page 3570 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3582 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3583 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3584 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3590 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3591 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3592 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Mechanical Specifications Radiator: Mechanical Specifications Radiator to radiator support bolts 53 - 71 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Mechanical Specifications > Page 3595 Radiator: Pressure, Vacuum and Temperature Specifications Pressure Test 20 psi Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 3596 Radiator: Service and Repair Removal 1. Drain the cooling system. 2. Remove the air cleaner outlet tube. 3. Position the (A) overflow tube clamp back and disconnect the (B) radiator overflow tube from the (C) radiator filler neck. 4. Remove the fan shroud. 5. Position the hose clamp back and disconnect the upper radiator hose from the radiator. 6. Position the hose clamp back and disconnect the lower radiator hose. 7. Disconnect the two transmission cooling lines. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 3597 8. Remove the bolts. 9. Remove the bolt. 10. Squeeze to release the buckle. 11. Squeeze to release the anti rattle clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 3598 12. Slide the A/C condenser out of the locations. 13. Lift the radiator up. 14. Lift the radiator up and remove from the vehicle. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure Test 13-18 psi Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3607 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3608 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3611 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 3612 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Partially drain the cooling system. For additional information, refer to Cooling System. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 8-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3616 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations > Page 3620 Temperature Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. 1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C104, circuit 39 (RD/WH), and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid range. Key OFF. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations > Page 3621 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature Starts to open 183-190 F Fully open 210 F Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3628 Thermostat: Service and Repair Removal 1. Partially drain the cooling system. 2. Remove the upper radiator hose. 3. Position the hose clamp back and remove the water bypass hose from the water hose connection. 4. Remove the two bolts from the water hose connection. 5. CAUTION: Do not pry on the water hose connection to remove. Remove the (A) water hose connection, the (B) water thermostat and the (C) thermostat gasket. Clean and inspect the mating surfaces. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3629 1. Note: Coat the new thermostat gasket with Gasket and Trim Adhesive F3AZ-19B508-AA or equivalent prior to installation. Install the new thermostat gasket. 2. Install the water thermostat into the water hose connection. - Align the notch in the thermostat with the notch in the water hose connection. 3. Install the water hose connection. 4. Install the water bypass tube. 1 Position the water bypass tube and hose clamps. 2 Tighten the hose clamps. 5. Install the upper radiator hose. 6. Fill the cooling system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat housing bolts 12 - 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 15 - 21 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump > Page 3637 Water Pump: Specifications Water pump pulley bolts 12 - 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3638 Water Pump: Service and Repair Removal 1. Remove the fan shroud. 2. Drain the cooling system. 3. Remove the accessory drive belt. 1 Turn the tensioner pulley clockwise. 2 Remove the accessory drive belt. 4. Remove the water bypass hose. 1 Loosen the water bypass hose clamps. 2 Remove the water bypass tube. 5. Loosen the water heater hose clamp and disconnect the water heater hose from the water pump. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3639 6. Remove the two retaining nuts and position the engine control sensor wiring aside. 7. Remove the bolts and the water pump pulley. 8. Remove the bolts and remove the water pump from the engine front cover. 9. Loosen the water pump inlet hose clamp and remove the water pump. Installation 1. Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A and a suitable plastic or wooden scraper to clean the gasket surfaces of the engine from cover and water pump. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3640 2. Install the water pump inlet hose on the water pump. 3. Position the water pump and install the bolts. 4. Position the engine control sensor wiring, and install the two nuts. 5. Install the water pump pulley. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3641 6. Install the water heater hose and clamp. 7. Install the water bypass tube. 1 Position the water bypass tube. 2 Install the two water bypass hose clamps. 8. Position the accessory drive belt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3642 9. Install the accessory drive belt. 1 Turn the tensioner clockwise. 2 Install the belt. 10. Install the fan shroud. 11. Fill the cooling system. 12. Start the engine and check for leaks. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3648 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3649 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3650 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3651 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3652 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3653 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3654 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3655 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3656 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3657 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3658 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3659 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3660 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3661 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3662 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3663 Catalytic Converter: Specifications Three-Way Catalytic Converter Bolts and Nut 25 - 34 ft.lb Three-Way Catalytic Converter-to-Exhaust Manifold Bolts (4.0L SOHC) 27 - 37 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3664 Catalytic Converter: Description and Operation Overview Generic Catalyst and Exhaust System The Catalytic Converter and Exhaust Systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides Of Nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either Platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can br brst accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3665 the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the H02S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the H02S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > LH and RH Catalytic Converter: Service and Repair LH and RH Removal 1. Remove the rear dual TWC. 2. Disconnect the four heated oxygen sensor (HO2S) connectors. 3. Remove the support insulator bracket bolt. 4. Note: The RH side is shown; the LH side is similar. Remove the four bolts. 5. Remove the gaskets and the RH and LH three way catalytic converters (TWC). Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > LH and RH > Page 3668 1. Note: Before installing the TWCs, install new gaskets. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > LH and RH > Page 3669 Catalytic Converter: Service and Repair Rear Dual Removal 1. Remove the muffler. 2. Remove the four (A) bolts and (B) nuts. 3. Remove the three way catalytic converter (TWC) and discard the two exhaust converter outlet gaskets. Installation 1. Note: Before installing the TWCs, install new gaskets. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold bolts 30 ft.lb -- When installing the exhaust manifold outlet bolts, run down each bolt half-way prior to final tightening. Exhaust manifold shield bolts 61 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH Exhaust Manifold: Service and Repair LH Removal and Installation 1. Discharge and recover the air conditioning system. 2. Remove the A/C compressor. 3. Disconnect the spark plug wires and remove the retaining brackets. 4. Disconnect the A/C manifold and tube and the condenser to evaporator tube from the A/C condenser core. 5. Remove the nut and oil level indicator tube. 6. Remove the wheel and tire. 7. Remove the pin type retainers and the wheel well apron. 8. Remove the nuts, studbolts and the LH exhaust manifold. 9. Clean and inspect the exhaust manifold and cylinder block surface. 10. Note: When installing the exhaust manifold outlet bolts, run down each bolt half-way prior to final tightening. To install reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3675 Exhaust Manifold: Service and Repair RH Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube. 3. Remove the drive belt tensioner. 4. Disconnect the generator electrical connectors. 5. Remove the generator bracket with the generator attached. 6. Remove the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3676 7. Remove the wheel and tire. 8. Remove the pin type retainers and the wheel well apron. 9. Remove the EGR valve to exhaust manifold tube. 10. Disconnect the spark plug wires and remove the retaining brackets, if needed. 11. Remove the bolts and the shield. 12. Remove the eight bolts and the exhaust manifold. 13. Clean and inspect the exhaust manifold and cylinder block surface. Installation 1. Note: When installing these bolts, run down each bolt half-way prior to final tightening. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3677 Position the exhaust manifold and install the eight bolts. 2. Install the shield and the bolts. 3. Install the spark plug wires and the retaining brackets. 4. Install the EGR valve to exhaust manifold tube. 5. Position the wheel well apron and install the pin type retainers. 6. Install the wheel and tire. 7. Install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3678 8. CAUTION: The front end accessory drive bracket bolts require special torque values. Proper tightening is necessary to prevent excessive accessory drive vibrations. Note: Make sure to tighten the generator bracket in two steps. Install the generator bracket and tighten the bolts in sequence. Step 1: Tighten bolts 1 and 2 to 35 Nm (26 ft. lbs.). - Step 2: Tighten bolt 3 to 65 Nm (48 ft. lbs.). 9. Tighten the remaining bolt. 10. Install the drive belt tensioner. 11. Install the air cleaner outlet tube. 12. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust inlet pipe-to-exhaust manifold bolts 26 - 33 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair Heat Shield: Service and Repair 1. Disconnect the battery cable. 2. Raise the vehicle. 3. Inspect the catalytic converter and muffler for loose or missing heat shields. 4. Install worm clamps for heat shields that are loose. - Use one of the following clamps: FOTZ-5A231-A or W705949-S300. - Trim off the excess ear of the worm clamp. 5. If the heat shields are missing, install new heat shields. If new heat shields are not available, install a new catalytic converter. 6. Lower the vehicle. 7. Reconnect the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 00-8-3 > Apr > 00 > Exhaust/Driveshaft - Rubbing Noise On R/H Turns Muffler: Customer Interest Exhaust/Driveshaft - Rubbing Noise On R/H Turns Article No. 00-8-3 DATE: 04/17/2000 NOISE - "RUBBING" FROM REAR OF VEHICLE DURING RIGHT HAND TURNS - VEHICLES EQUIPPED WITH 5.0 L ENGINE BUILT THROUGH 1/5/2000 FORD: 1996-2000 EXPLORER MERCURY: 1996-2000 MOUNTAINEER ISSUE Some vehicles equipped with 5.OL engine may exhibit a rubbing noise during right hand turns from the rear of the vehicle. This may be due to insufficient clearance between the muffler hanger rod and the rear driveshaft This condition generally occurs when the muffler inlet pipe slip joint does not completely slide over the converter outlet pipe and causes the muffler assembly to pull inboard during assembly. ACTION Replace the muffler assembly and hanger bracket. The revised muffler assembly (YL2Z-5230-AA) has hanger rods that have been re-oriented 90 degrees which when used with the new hanger bracket (F57Z-5A246-A) allows the system to swing fore-aft (same as the 4.OL OHV system) and prevents the potential contact with the rear driveshaft. Refer to section 309-00 of the appropriate model year Workshop Manual for standard exhaust system repair procedures. NOTE: When the new muffler assembly (YL2Z-5230-AA) is installed, the new hanger bracket (F57Z-5A246-A) must also be used. PART NUMBER PART NAME YL2Z-5230-AA Muffler Assembly F57Z-5A246-A Hanger Bracket OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 597997, 702000, 702200,702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 00-8-3 > Apr > 00 > Exhaust/Driveshaft - Rubbing Noise On R/H Turns Muffler: All Technical Service Bulletins Exhaust/Driveshaft - Rubbing Noise On R/H Turns Article No. 00-8-3 DATE: 04/17/2000 NOISE - "RUBBING" FROM REAR OF VEHICLE DURING RIGHT HAND TURNS - VEHICLES EQUIPPED WITH 5.0 L ENGINE BUILT THROUGH 1/5/2000 FORD: 1996-2000 EXPLORER MERCURY: 1996-2000 MOUNTAINEER ISSUE Some vehicles equipped with 5.OL engine may exhibit a rubbing noise during right hand turns from the rear of the vehicle. This may be due to insufficient clearance between the muffler hanger rod and the rear driveshaft This condition generally occurs when the muffler inlet pipe slip joint does not completely slide over the converter outlet pipe and causes the muffler assembly to pull inboard during assembly. ACTION Replace the muffler assembly and hanger bracket. The revised muffler assembly (YL2Z-5230-AA) has hanger rods that have been re-oriented 90 degrees which when used with the new hanger bracket (F57Z-5A246-A) allows the system to swing fore-aft (same as the 4.OL OHV system) and prevents the potential contact with the rear driveshaft. Refer to section 309-00 of the appropriate model year Workshop Manual for standard exhaust system repair procedures. NOTE: When the new muffler assembly (YL2Z-5230-AA) is installed, the new hanger bracket (F57Z-5A246-A) must also be used. PART NUMBER PART NAME YL2Z-5230-AA Muffler Assembly F57Z-5A246-A Hanger Bracket OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 597997, 702000, 702200,702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3698 Muffler: Specifications Muffler to Converter Bolts 25 - 34 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3699 Muffler: Service and Repair Removal WARNING: Allow the engine to cool before attempting any exhaust system repair. Hot exhaust system components can cause severe burns. 1. Remove the three bolts. 2. Remove and discard the exhaust converter outlet gasket. 3. Disconnect the RH torsion bar link. - Remove the nut and position the torsion bar link out of the way. 4. Pry the rear support slide out of the rubber insulator. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3700 5. Pry the double support slides away from the insulators. 6. Remove the muffler. Slide the muffler forward over the rear axle while twisting the muffler until the muffler and tailpipe is removed. Installation 1. Install the muffler and tailpipe assembly over the rear axle and twist the muffler into position. 2. Note: Before installing the muffler into the rubber insulators, apply a soap solution to the support slides. Push the double support slides into the rubber insulators. 3. Push the rear support slide into the insulator. 4. Position the RH torsion bar and install the nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3701 5. Install a new rear dual exhaust converter outlet gasket. 6. Install the three bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 3713 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 3714 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3720 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3721 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 3726 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 3727 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3733 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3734 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3735 Powertrain Control Module: Specifications Powertrain Control Module Bolt 6 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3736 Powertrain Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3737 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3738 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3739 Part (2 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3740 Part (3 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3741 Powertrain Control Module: Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3742 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3745 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3749 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3750 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3755 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3756 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3757 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3761 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3762 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3768 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3769 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3770 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3771 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3780 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3781 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3782 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3783 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3784 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3785 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3786 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3787 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3788 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3789 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3790 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3791 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3792 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3798 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3799 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3800 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3801 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3802 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3803 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3804 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3805 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3806 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3807 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3808 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3809 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3810 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3811 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3812 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3813 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3814 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 3817 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 3818 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3822 Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3826 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3827 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3830 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 3831 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Partially drain the cooling system. For additional information, refer to Cooling System. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3835 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3836 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3839 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3840 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3850 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3851 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3852 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3856 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3857 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3861 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3869 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3870 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3871 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3872 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3873 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3874 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3875 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3876 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3877 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3878 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3879 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3880 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3881 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3882 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3883 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3884 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations > Page 3887 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3898 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3899 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3902 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3903 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3904 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3905 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3906 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The front HO2S: ^ creates a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the PCM used to calculate catalytic converter integrity. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3907 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3908 Syncro Positioning Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3912 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3913 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3914 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3915 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3919 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3920 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3921 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3925 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3926 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3927 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3928 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3929 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3930 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3937 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Diagram 64-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3951 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3956 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3957 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3958 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3959 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3964 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3965 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3966 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3967 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3974 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3975 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3979 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3980 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3981 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3991 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3992 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3993 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3994 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3995 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3996 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3997 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3998 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3999 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4001 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4002 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4003 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4009 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4010 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4011 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4012 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4013 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4014 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4015 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4016 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4017 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4018 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4019 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4020 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4021 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4022 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4023 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4024 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4025 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 4028 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 4029 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4033 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4034 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4037 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4038 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4047 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4048 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4049 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4050 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4051 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4052 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4053 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4054 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4055 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4056 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4057 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4058 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4059 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4065 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4066 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4067 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4068 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4069 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4070 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4071 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4072 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4073 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4074 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4075 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4076 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4077 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4083 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4084 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4085 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4086 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4087 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4090 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4091 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4092 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4096 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 750 RPM Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4112 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4113 Fuel Pressure Gauge Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 4124 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. 1. Use the special tool to pull the spark plug wire off the spark plug with a twisting motion. 2. Squeeze the locking tab and twist while pulling upward to remove the spark plug wires from the ignition coils. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 4125 1. Connect the spark plug wires to the ignition coils. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of spark plug and ignition coil boots of the spark plug wire. 2. Install the LH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 4126 3. Install the RH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 4131 Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4132 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. ............................................................. AWSF32EG LH Original Spark Plug Type ............................ ................................................................................................................................................... AWSF32E New Spark Plug Type (Either Side) ................................................................................... ................................................................................ AWSF32EE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4133 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4137 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4138 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4146 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4147 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4148 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4149 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4153 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4154 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4163 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4164 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4165 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4166 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4167 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4168 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4169 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4175 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4176 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4177 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4178 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4179 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4180 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4181 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4190 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4191 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4192 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4193 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4194 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4195 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4196 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4197 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4198 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4199 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4200 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4201 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4202 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4208 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4209 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4210 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4211 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4212 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4213 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4214 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4215 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4216 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4217 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4218 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4219 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4220 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4221 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4222 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4223 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4224 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 4227 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 4228 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 4232 Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4236 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4237 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4240 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 4241 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Partially drain the cooling system. For additional information, refer to Cooling System. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4245 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4246 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4249 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4250 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 Data Link Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 4271 Data Link Connector: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Module Communications Network / Information Bus. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4280 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4281 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4287 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4288 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4293 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4294 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4300 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4301 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4302 Powertrain Control Module: Specifications Powertrain Control Module Bolt 6 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4303 Powertrain Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4304 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4305 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4306 Part (2 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4307 Part (3 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4308 Powertrain Control Module: Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4309 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 4312 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4322 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4323 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4324 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control Valve Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4328 Idle Air Control Valve: Description and Operation Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly with Vent/Filter Hitachi Idle Air Control (IAC) Valve Assembly with Air-Assist Injectors The Idle Air Control (IAC) valve assembly controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the AC duty cycle in order to achieve the desired rpm. On applications with air-assisted injectors, the IAC valve also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4329 NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4330 Idle Air Control Valve: Testing and Inspection 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an Engine EAR probe near the IAC valve and the inlet tube, or create a 6.35 mm (0.25 in) - 12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4331 Idle Air Control Valve: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Disconnect the idle air control (IAC) valve electrical connector. 4. Remove the IAC valve and discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Install a new IAC valve gasket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications Multiplex Communication Network: Specifications Heat shrink tube overlap 12.7 mm Wire insulation removal length (twist side) 37.2 mm Wire insulation removal length (receiving side) 19.5 mm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications > Page 4335 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Multiplex Communication Network: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Multiplex Communication Network: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4349 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4350 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 Diagram 14-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation Multiplex Communication Network: Description and Operation The vehicle has two separate module communication networks. The Standard Corporate Protocol (SCP) which is an unshielded twisted pair cable (data bus plus, circuit 914 [T/O] and data bus minus, circuit 915 [P/LB]) and the International Standards Organization (ISO) 9141 Network via a single wire (circuit 70 [LB/W]). Both networks can be connected to scan tool at one connector called the Data Link Connector (DLC). This makes troubleshooting these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 4355 be found under the instrument panel between the steering column and the radio. The ISO 9141 communication network does not permit inter-module communication. When the scan tool communicates to modules on the ISO 9141 communication network, the scan tool must ask for all information; the modules cannot initiate communications. The SCP will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+) or a termination resistor is lost. This faulted condition is detected and reported to the host by the module's network bus interface circuits. Unlike the SCP, the ISO 9141 communication network will not function if the wire is shorted to ground or battery positive voltage (B+). Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. There are three modules linked to the SCP communication network and seven modules linked to the ISO 9141 communication network. SCP Communication Network The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. The Passive Anti-theft System (PATS) module is on the SCP communication network. The PATS module contains circuitry to connect the vehicle electrical system, the transceiver module, the vehicle module communications network and the vehicle theft indicator located in the instrument cluster. The PATS module uses a microprocessor to control the system functions. The PATS module microprocessor stores the ignition key codes in non-volathe memory. The PATS module can be diagnosed through the data link connector. For additional information, refer to Antitheft and Alarm Systems. The Electronic Automatic Temperature Control (EATC) module is linked to the SCP communication network. The EATC module controls automatic climate functions that maintain the interior at a constant temperature setting. For additional information, refer to Heating and Air Conditioning. ISO 9141 Communication Network The Restraint Control Module (RCM) module is on the ISO 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. For additional information, refer to Air Bag Systems. The Parking Aid Module (PAM) is on the ISO 9141 communication network. The PAM controls the parking aid system For additional information, See: Accessories and Optional Equipment/Collision Avoidance and Parking Assist Systems The Generic Electronic Module (GEM)/Central Timer Module (CTM) is on the ISO 9141 communication network. The GEM is equipped on vehicles with four-wheel drive or vehicles with power windows. The CTM is equipped on vehicles with two-wheel drive or vehicles without power windows. The GEM controls a variety of systems: ^ 4x4 ^ Windshield wipers ^ Courtesy lamps ^ One touch down power windows, etc. ^ Warning chimes/lamps For additional information, refer to Multifunction Electronic Control Module. The Remote Anti-theft Personality (RAP) module is on the ISO 9141 communication network. The RAP module controls the keyless remote entry and active anti-theft of the vehicle. For additional information, refer to Keyless Entry and Antitheft and Alarm Systems. The 4-wheel anti-lock brake control module is on the ISO 9141 communication network. The 4-wheel anti-lock brake control module controls the brake pressure to the four wheels to keep the vehicle under control while braking. For additional information, refer to Antilock Brake System. The air suspension system is a computer controlled suspension system. The rear shock absorber contains an integrated air spring. The rear air springs provide automatic load leveling and a ride adjustment with a total span of 50 mm (2 in). The air suspension control module programming has a time delay compensation for normal suspension travel over rough roads so the air suspension system will not attempt to continuously adjust vehicle ride height. There is one height sensor mounted in the rear of the vehicle. The height sensors have a total travel range of 80 mm (3 in). For additional information, refer to Electronic Level Control. The Driver Seat Module (DSM) is connected on the SCP communication network. The DSM controls the power seat and memory functions. For additional information, refer to Seats. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 4356 Multiplex Communication Network: Description and Operation Principles of Operation Some modules support the ability to change specified factory configuration settings and preset preference items. The process used to change the settings and customer preference items is module configuration. The methods of module configuration used on these vehicles are: ^ Tire Size and Axle Ratio ^ Operational Strategy (4x2/4x4) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network Multiplex Communication Network: Testing and Inspection Module Communications Network Initial Inspection 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 5 (10A) ^ Damaged wiring harness ^ Loose or corroded connectors ^ 4-wheel anti-lock brake control module ^ Restraint Control Module (RCM) ^ Generic Electronic Module (GEM)/Central Timer Module (CTM) ^ Powertrain control module (PCM) ^ Parking aid module (PAM) (optional) ^ Remote Anti-theft Personality (RAP) module (optional) ^ Air suspension control module (optional) ^ Passive Anti-theft System (PATS) module ^ Driver Seat Module (DSM) (optional) ^ Electronic Automatic Temperature Control (EATC) module (optional) 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position is in RUN. If the scan tool still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/Pinpoint Tests/Test M: No Module/Network Communication - No Power to Scan Tool 4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4359 PC1 Test A: 4WABS Control Module Does Not Respond to Diagnostic Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4360 A1 - A2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4361 A3 - A4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4362 A5 - A6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4363 B1 - B2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4364 C1 - C2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4365 D1 - D2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4366 D3 - D4 Test E: PCM Does Not Respond to the Diagnostic Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4367 E1 - E2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4368 E3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4369 E4 - E5 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4370 E6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4371 F1 - F2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4372 G1 - G2 Test H: DSM No Response Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4373 H1 - H2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4374 H3 - H4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4375 H5 - H6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4376 I1 - I2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4377 I3 - I4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4378 J1 - J2 Test K: No Module/Network Communication - ISO 9141 Network Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4379 K1 - K2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4380 K3 - K4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4381 K5 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4382 K6 - K7 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4383 K8 K9 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4384 K10 - K11 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4385 K12 - K13 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4386 K14 - K15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4387 K16 K17 K18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4388 K19 - K20 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4389 K21 K22 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4390 K23 Test L: No Module/Network Communication - SCP Network L1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4391 L2 - L3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4392 L4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4393 L5 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4394 L6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4395 L7 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4396 L8 M1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4397 M2 - M4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4398 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4399 Multiplex Communication Network: Testing and Inspection Module Configuration Inspection and Verification 1. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Damaged wiring harness ^ Loose or corroded connectors ^ 4-wheel Anti-lock Brake Control Module (4WABS) ^ Generic Electronic Module (GEM) 2. If the concern remains after inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch is in RUN position. 3. If the scan tool still does not communicate with the vehicle, refer to Module Communication Network (Information Bus). 4. Refer to the Symptom Chart. See: Diagnosis By Symptom Customer Preference Items NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting customer preference items and supports the specific item to be configured in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the customer preference item to be programmed. Refer to the Module Configuration Index. See: Scan Tool Testing/Module Configuration Index 3. Select Customer Preference Items on the scan tool. 4. Select Module Option Content. 5. Select the item to be enabled or disabled. 6. Enable or disable the item as necessary to reflect the customer preference. Operational Strategy NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting tire size and axle ratio configuration in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the Operational Strategy to be programmed. Refer to the Module Configuration Index. See: Scan Tool Testing/Module Configuration Index 3. Select Operational Strategy. 4. Select the vehicle. 5. Select 4x4 for a 4x4 vehicle. Select 4x2 for a 4x2 vehicle. Tire Size and Axle Ratio NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting tire size and axle ratio configuration in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the Tire Size and Axle Ratio configuration. 3. Select Customer Preference Items. 4. Select Tire Size and Axle Ratio on the scan tool. 5. Select the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4400 6. Enter the correct value for the vehicle according to the chart and finish the routine. If the tire size is not listed on the chart, Go to step 7. 7. Position the vehicle on level ground. Make sure the load weight is within the specific vehicle application. NOTE: The following steps will calculate tire revolutions per mile. This will provide the number that needs to be entered on the scan tool. 8. Inflate the tires to the specified rating. NOTE: Tire pressure must be set when the tires are cold. 9. Measure the rear tire height from the ground to the top of the tire in inches. 10. Divide 20,168 by the tire height measurement. This is the revolutions per mile. 11. Enter the revolutions per mile (rev/mile) on the scan tool and finish the routine. Module Configuration Index NOTE: Do not contact the As-Built Data Center unless the scan tool instructs you to do so. The scan tool will not allow you to use as-built data information unless the scan tool first prompts you for the As-Built Data Center information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4401 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4402 A1 - A3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 4403 Multiplex Communication Network: Service and Repair Communication Circuit Wiring Repair Heat Gun SPECIAL SERVICE TOOLS 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Strip the wires. 3. Solder the wires 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 4404 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment Multiplex Communication Network: Tools and Equipment Recommended Tools Heat Gun Recommended Supplies Raychem SCT(R) heat shrink tubing, Motorcraft part number WT-5627 .................................................................................................. ESB-M99D56-A2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 4407 Multiplex Communication Network: Tools and Equipment Diagnostic Special Service Tool(S) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4411 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4415 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4416 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 4420 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4428 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4429 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4430 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4431 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4432 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4433 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4434 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4435 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4436 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4437 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4438 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4439 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4440 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4441 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4442 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4443 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations > Page 4446 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4464 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4465 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The front HO2S: ^ creates a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the PCM used to calculate catalytic converter integrity. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4466 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4467 Syncro Positioning Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4471 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4472 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4473 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4474 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4484 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4485 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4491 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4492 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Powertrain Control Module: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4497 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 4498 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4504 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4505 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4506 Powertrain Control Module: Specifications Powertrain Control Module Bolt 6 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4507 Powertrain Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4508 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4509 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4510 Part (2 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4511 Part (3 Of 3) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4512 Powertrain Control Module: Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4513 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 4516 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4520 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4521 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4526 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4527 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4528 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4529 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4538 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4539 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4540 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4541 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4542 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4543 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4544 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4545 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4546 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4547 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4548 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4549 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4550 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4556 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4557 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4558 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4559 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4560 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4561 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4562 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4563 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4564 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4565 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4566 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4567 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4568 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4569 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4570 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4571 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4572 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 4575 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 4576 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 4580 Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4584 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4585 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4588 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 4589 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Partially drain the cooling system. For additional information, refer to Cooling System. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4593 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4594 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4597 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4598 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4608 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4609 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4610 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4614 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4615 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4619 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4627 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4628 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4629 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4630 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4631 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4632 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4633 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4634 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4635 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4636 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4637 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4638 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4639 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4640 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4641 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4642 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Component Locations > Page 4645 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4663 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4664 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The front HO2S: ^ creates a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the PCM used to calculate catalytic converter integrity. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4665 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4666 Syncro Positioning Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4670 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4671 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4672 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4673 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4677 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4678 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4679 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4683 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4684 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4685 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4686 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4687 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4688 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Diagram 64-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4709 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4713 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4714 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4715 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4719 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4720 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4721 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4722 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4723 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4724 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Diagram 64-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4745 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4751 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4752 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4753 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4754 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4755 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4756 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4757 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4758 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4759 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4760 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4761 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4762 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4763 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4764 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4765 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4766 Catalytic Converter: Specifications Three-Way Catalytic Converter Bolts and Nut 25 - 34 ft.lb Three-Way Catalytic Converter-to-Exhaust Manifold Bolts (4.0L SOHC) 27 - 37 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4767 Catalytic Converter: Description and Operation Overview Generic Catalyst and Exhaust System The Catalytic Converter and Exhaust Systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides Of Nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either Platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can br brst accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4768 the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the H02S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the H02S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > LH and RH Catalytic Converter: Service and Repair LH and RH Removal 1. Remove the rear dual TWC. 2. Disconnect the four heated oxygen sensor (HO2S) connectors. 3. Remove the support insulator bracket bolt. 4. Note: The RH side is shown; the LH side is similar. Remove the four bolts. 5. Remove the gaskets and the RH and LH three way catalytic converters (TWC). Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > LH and RH > Page 4771 1. Note: Before installing the TWCs, install new gaskets. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > LH and RH > Page 4772 Catalytic Converter: Service and Repair Rear Dual Removal 1. Remove the muffler. 2. Remove the four (A) bolts and (B) nuts. 3. Remove the three way catalytic converter (TWC) and discard the two exhaust converter outlet gaskets. Installation 1. Note: Before installing the TWCs, install new gaskets. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications Canister Purge Valve Bracket Retaining Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4777 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4778 Canister Purge Control Valve: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4779 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve EVAP Canister Purge Valve Focus, Escort, Taurus/Sable, Mustang, and LS6/LS8 (EVAP Canister Purge Valve) The EVAP canister purge valve is the part of the Enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is normally closed valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4780 Canister Purge Control Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the battery tray. For additional information, refer to Battery. 3. Disconnect the tubes. 1 Disconnect the electrical connector. 2 Disconnect the tubes from the evaporative emission canister purge valve (EVAP canister purge valve). WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Disconnect the evaporative emission canister purge valve and bracket. ^ Remove the bolt. 5. Remove the evaporative emission canister purge valve. 1 Disconnect the vacuum line from the evaporative emission canister purge valve. 2 Remove the evaporative emission canister purge valve. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4781 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For additional information refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 4785 6. Disconnect the canister vent hose. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Evaporative Emissions Canister Bolts 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4789 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4790 Evaporative Emission Control Canister: Service Precautions WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation Evaporative Emission Control Canister: Description and Operation The Evaporative Emissions (EVAP) canister: ^ is located under the rear of the vehicle. ^ contains activated carbon. ^ stores fuel vapors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation > Page 4793 Evaporative Emission Control Canister: Description and Operation Principles of Operation (How Does It Work ?) Fuel vapors from the fuel tank are stored in the EVAP canister. When the engine is running, the vapors are purged from the EVAP canister for combustion. OBD II vehicles sometimes use multiple canisters, which is dependent upon the size and number of the fuel tanks used on a specific vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4794 Evaporative Emission Control Canister: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For additional information refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4795 6. Remove the canister vent solenoid and the evaporative emission tube. 1 Disconnect the canister vent solenoid hose from the canister vent solenoid. 2 Remove the canister vent solenoid. 3 Remove the evaporative emission canister purge sleeve. 4 Remove the evaporative emission tube. 7. Remove the evaporative emission canister from the evaporative emission canister bracket. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair NOTE: Lubricate all O-ring seals with MERPOL(R) O-ring Seal Lubricant or equivalent meeting Ford specification ESE-M99B144-B. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation The Evaporative Emission (EVAP) system test port: ^ is located on the EVAP canister purge outlet tube near the EVAP canister purge valve. ^ is used to connect the Evaporative Emissions System Leak Tester to the EVAP system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation > Page 4799 Evaporative System Service Port: Service and Repair REMOVAL 1. Remove the clip. 2. Disconnect the hoses. 3. Remove the test port assembly. ^ Disconnect the fitting. ^ Remove the test port assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information Leak Detection Valve: Technician Safety Information WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information > Page 4805 Leak Detection Valve: Vehicle Damage Warnings CAUTION: ^ The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. ^ The evaporative emission system must not be pressurized to more than 3.48 kPa (14 inches/H2O) or damage to the evaporative emission system may occur. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation Leak Detection Valve: Description and Operation The canister vent solenoid: ^ is normally open. ^ seals the evaporative emissions system for the Inspection And Maintenance (I/M 240) test and OBD II leak and pressure tests. ^ is mounted to the evaporative emissions canister bracket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation > Page 4808 Leak Detection Valve: Description and Operation Principles of Operation (How Does It Work ?) During the Evaporative Emission Running Loss System Monitor Test, Evaporative Emissions Repair Verification Drive Cycle, and the Evaporative Emission System leak Test, the canister vent solenoid is closed to allow either a vacuum to be drawn on the fuel tank or to hold a specified pressure in the system. The canister vent solenoid is normally open. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation > Page 4809 Leak Detection Valve: Description and Operation 2000 All (Except diesel/Propane/Villager) Canister Vent Solenoid Typical Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the monitor run. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid Leak Detection Valve: Service and Repair Canister Vent Solenoid REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the Evaporative Emissions (EVAP) canister. For additional information, refer to Evaporative Emission Control Canister. 3. Remove the canister vent solenoid. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission canister and bracket assembly. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid > Page 4812 Leak Detection Valve: Service and Repair Canister Vent Solenoid Closing Procedure Worldwide Diagnostic System (WDS) SPECIAL SERVICE TOOL(S) CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. 1. Connect the scan tool and select the output test mode. 2. Select the Fuel Tank Pressure (FTP) and the volts (V) Parameter Identification (PID) for monitoring. 3. Select the ALL OFF mode. 4. Close the canister vent solenoid by pushing the START button on the scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4816 Liquid Vapor Separator: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4817 Liquid Vapor Separator: Description and Operation The Fuel Vapor Vent Valve (FVV) assembly is mounted on the top of the fuel tank. It is used to control the flow of fuel vapors entering the EVAP system. The head portion of the assembly prevents the fuel tank from overfilling during refueling. The assembly also has a spring float, which prevents liquid fuel from entering the vapor delivery system under severe handling or vehicle rollover conditions. In the upright position, the open bottom of the float will lift and shut off the orifice. Under severe handling conditions, the spring will push the float closed when angles allow liquid fuel to reach the orifice. In a rollover condition, the weight of the open bottom float and spring pressure will close the orifice. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4818 Liquid Vapor Separator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Drain the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 4. Lower the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 5. Remove the EVAP canister tube from the fuel vapor vent valve. 6. Remove the fuel vapor vent valve. ^ Press down and rotate the fuel vapor vent valve counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation On-Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System Focus, Escort, and Contour/Mystique/Cougar (ORVR EVAP System) LS6/LS8 (ORVR EVAP System) Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Page 4822 The basic elements forming the ORVR system operation are as follows when fuel is dispensed: 1. The fuel filler pipe forms a seal to prevent vapors from escaping the fuel tank, while liquid is entering the fuel tank (liquid in the one inch diameter tube blocks vapors from rushing back up the fuel filler pipe). 2. A fuel vapor control valve controls the flow of vapors out of the fuel tank (valve closes when liquid level reaches a height associated with the fuel tank usable capacity). This valve accomplishes the following: a. Limits the total amount of fuel that can be dispensed into the fuel tank. b. Prevents liquid gasoline from exiting the fuel tank when submerged (and also when tipped well beyond a horizontal plane as part of the vehicle roll-over protection in road accidents). c. Minimizes vapor flow resistance during anticipated refueling conditions. 3. Fuel vapor tubing connects the fuel vapor control valve to the EVAP canister. This routes the fuel tank vapors (displaced by the incoming liquid) to the EVAP canister. 4. A check valve in the bottom of the fuel filler pipe prevents liquid from rushing back up the fuel filler pipe during the liquid flow variations associated with the filler nozzle shut-off. Between refueling events, the EVAP canister is purged with fresh air so that it may be used again to store vapors accumulated engine soaks or subsequent refueling events. The vapors drawn off of the carbon in the EVAP canister are consumed in the engine. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications EGR Vacuum Regulator Solenoid Nuts 8 - 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4827 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4828 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid Graph EGR Vacuum Regulator Solenoid Data The EGR vacuum regulator solenoid is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4829 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the (A) electrical connector and the (B) vacuum hoses from the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid. 3. Remove the nuts and the EGR vacuum regulator solenoid. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Tube Fittings 34 - 48 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4833 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4834 EGR Tube: Description and Operation Orifice Tube Assembly Orifice Tube Assembly The orifice tube assembly is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4835 EGR Tube: Service and Repair REMOVAL 1. Disconnect the EGR pressure transducer hoses. 2. Disconnect the EGR tube fittings. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4839 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4840 EGR Valve: Description and Operation Exhaust Gas Recirculation Valve Exhaust Gas Recirculation Valve Exhaust Gas Recirculation Valve Graph The EGR valve in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4841 EGR Valve: Service and Repair REMOVAL 1. Disconnect the EGR valve vacuum connection. 2. Disconnect the EGR tube upper fitting. 3. Remove the two bolts and the EGR valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Carefully clean all sealing surfaces and install a new EGR valve gasket. NOTE: The EGR valve sealing surfaces are soft metals. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4845 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4846 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4847 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4848 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Service Precautions Positive Crankcase Ventilation: Service Precautions CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will adversely affect the fuel economy and engine ventilation and result in shorter engine life. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Service Precautions > Page 4852 Positive Crankcase Ventilation: Description and Operation Overview PCV System The Positive Crankcase Ventilation (PCV) System cycles crankcase gases back through the engine where they are burned. The PCV valve regulates the amount of ventilating air and blow-by gas to the intake manifold and prevents backfire from traveling into the crankcase. The PCV valve should be mounted in a vertical position. On some applications, the PCV system is connected to the evaporative emission system (refer to the VECI decal). CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will adversely affect the fuel economy and engine ventilation and result in shorter engine life. HARDWARE PCV Internal Drawing Typical PCV Vacuum Connector Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Service Precautions > Page 4853 Positive Crankcase Ventilation: Testing and Inspection For further information regarding the diagnosis of this system, please refer to Computers and Control Systems; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Nuts 4.5 - 7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4858 Pressure Feedback Exhaust Sensor: Locations Rear of engine compartment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4859 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4860 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4861 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4870 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4871 Fuel Pressure Gauge Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 750 RPM Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal And Shaft Pivot Screw 9 - 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4878 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4879 Accelerator Pedal: Description and Operation The accelerator cable is controlled by an accelerator pedal and shaft. The pedal and shaft should travel smoothly from the idle to wide-open throttle positions. Failure to return or hesitation on return to the idle position must not occur. Surrounding components such as wiring, hoses, sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. The speed control speedometer cable and the accelerator cable are attached at the throttle lever on the throttle body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview NOTE: Care should be exercised when performing service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause bending. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4882 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable Accelerator Pedal: Service and Repair Cable REMOVAL 1. Remove the bolt and the accelerator control splash shield. 2. Disconnect the accelerator cable from the throttle body. 3. Separate the (B) accelerator cable from the (A) speed control actuator cable. 4. Disconnect the accelerator cable from the accelerator pedal and shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable > Page 4885 5. Collapse the clips at the dash panel and push the accelerator cable through the dash panel into the engine compartment and remove the accelerator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable > Page 4886 Accelerator Pedal: Service and Repair Pedal REMOVAL 1. Disconnect the accelerator cable from the accelerator pedal and shaft. See: Cable 2. Remove the accelerator pedal and shaft pivot screw, and remove the accelerator pedal and shaft. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4893 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4894 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4895 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4896 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4905 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4906 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4907 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4908 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4909 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4910 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4911 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4917 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4918 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4919 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4920 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4921 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4922 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4923 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4932 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4933 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4934 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4935 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4936 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4942 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4943 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4944 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4945 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4946 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4947 Fuel Filler Cap: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4948 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4949 Fuel Filler Cap: Description and Operation Fuel Filler Cap Fuel Filler Cap The fuel filler cap is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. The fuel tank filler cap: ^ relieves system pressure above 14 kPa (56.21 inches H2O). ^ relieves system vacuum below 3.8 kPa (15.26 inches H2O). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4954 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4955 Fuel Pressure Gauge Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair Fuel Injector Wiring Harness: Service and Repair REMOVAL 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect the fuel injector electrical connectors. 3. Disconnect the engine bulkhead connector. 4. Disconnect the Powertrain Control Module (PCM) connector. 5. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4960 6. Disconnect the water temperature indicator electrical connector. 7. Disconnect the Camshaft Position (CMP) sensor electrical connector. 8. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 9. Disconnect the transmission harness electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4961 10. Disconnect the engine oil pressure sending unit electrical connector. 11. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 12. Disconnect the ignition coil electrical connectors. 13. Disconnect the radio ignition interference capacitor electrical connector. 14. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 15. Remove the wiring harness from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Removal Tool SPECIAL SERVICE TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel Filter/Fuel Pressure Release 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Tool and push it into the fitting. 4. Separate the fittings. ^ Inspect for damage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4967 ^ Clean the fittings. CONNECT 1. Align the tube to the fitting and push until you hear a click. NOTE: Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-G to ease assembly. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4968 Fuel Line Coupler: Service and Repair R-Clip Fittings DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel Filter/Fuel Pressure Release 2. Remove the shipping tab by bending downward. 3. Spread the R-clip legs and push the clip into the fitting. 4. Separate the fitting from the tube. CONNECT 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil meeting Ford specification WSS-M2C153-G to the male tube end. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4969 3. Insert the R-clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube into the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4970 Fuel Line Coupler: Service and Repair Spring Lock Couplings SPECIAL SERVICE TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel Filter/Fuel Pressure Release 2. Remove the fuel tube clip. 3. Install the Spring Lock Coupler Tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4971 4. Close and push the Spring Lock Coupler Tool into the open side of the cage. 5. Separate the fitting. 6. Remove the Spring Lock Coupler Tool. CONNECT 1. Connect the fitting. ^ Inspect and clean both the coupling ends. ^ Lubricate the O-rings with clean engine oil meeting Ford specification WSS-M2C153-G. ^ Connect the fitting. ^ Pull on the fitting to make sure it is fully engaged. ^ Install the safety clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4972 Fuel Line Coupler: Service and Repair Vapor Tube Fittings DISCONNECT 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. CONNECT 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 4973 Fuel Line Coupler: Tools and Equipment Fuel Line Disconnect Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Fuel Pressure Regulator The fuel pressure regulator is attached to the fuel rail downstream of the fuel injectors. It regulates fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief valve. One side of the diaphragm senses fuel pressure and the other side is connected to the intake manifold vacuum. Fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the fuel injectors. Fuel pressure is high when engine vacuum is low. Excess fuel is bypassed through the fuel pressure regulator and returned through the fuel return line to the fuel tank. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Pulsation Damper: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information > Page 4984 Fuel Pressure Pulsation Damper: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4985 Fuel Pressure Pulsation Damper: Description and Operation Pulse Damper Pulse Damper The fuel rail pulse damper located on the fuel rail reduces fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4986 Fuel Pressure Pulsation Damper: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Relieve fuel pressure. 2. Remove the fuel pulse damper. 1 Disconnect the vacuum hose. 2 Remove the snap ring. 3 Remove the fuel pulse damper and O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil XO-10W30-DSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4995 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4996 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4997 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Injection Supply Manifold Bolts 8 - 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5001 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5002 Fuel Rail: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5003 Fuel Rail: Description and Operation The fuel injection supply manifold: ^ delivers fuel to the individual fuel injectors. ^ receives fuel from the fuel supply line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5004 Fuel Rail: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the intake manifold. For additional information, refer to Engine. 2. Relieve the fuel pressure. 3. Disconnect the fuel line. 4. Disconnect the fuel injector electrical connectors. 5. Remove the fuel injection supply manifold. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 5008 Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit. - For R and R of Fuel and Feed Lines - Quick line removal - Gold-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: 8110 - 10-Pc. Line Disconnect Set Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 5009 8107 - 7-Piece Line Disconnect Set Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5019 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5020 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5021 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5022 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5023 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5029 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5030 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5031 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5032 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5033 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 5034 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 5035 Fuel Filler Hose: Description and Operation The fuel filler pipe check valve is an integral part of the fuel tank or the fuel filler pipe. It is intended to prevent liquid fuel from re-entering the fuel filler pipe from the fuel tank on refueling or rollover conditions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 5036 Fuel Filler Hose: Service and Repair REMOVAL 1. Remove the fuel tank filler cap. 2. Remove the screws. 3. Remove the fuel tank filler pipe and the vent hose from the fuel tank and remove the fuel tank filler pipe. INSTALLATION 1. Install the fuel tank filler pipe and the vent hose. 1 Orient clamp bonding patch with top of the fuel tank. 2 Tighten the hose clamps. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 5037 2. Install the three fuel tank filler pipe screws. 3. Install the fuel tank filler cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5046 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5047 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5048 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5049 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5050 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5056 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5057 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5058 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5059 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5060 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 5064 Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 5065 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control Valve Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5075 Idle Air Control Valve: Description and Operation Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly with Vent/Filter Hitachi Idle Air Control (IAC) Valve Assembly with Air-Assist Injectors The Idle Air Control (IAC) valve assembly controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the AC duty cycle in order to achieve the desired rpm. On applications with air-assisted injectors, the IAC valve also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5076 NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5077 Idle Air Control Valve: Testing and Inspection 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an Engine EAR probe near the IAC valve and the inlet tube, or create a 6.35 mm (0.25 in) - 12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5078 Idle Air Control Valve: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Disconnect the idle air control (IAC) valve electrical connector. 4. Remove the IAC valve and discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Install a new IAC valve gasket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5082 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5083 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair REMOVAL NOTE: The 5.0L engine is shown, the 4.0L (push rod) engine is similar. 1. Remove the air cleaner outlet tube. ^ Loosen the clamps. ^ Disconnect the vent hose. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the screw clamps do not interfere with the throttle body cam. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5090 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5091 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5096 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5097 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5098 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5102 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5103 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5108 Mass Air Flow Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5109 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5110 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5111 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5118 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5119 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5123 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5124 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5125 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Bolts 8 - 10 Nm Throttle Body-to-upper Intake Manifold Bolts 8 - 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information Throttle Body: Technician Safety Information WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information > Page 5131 Throttle Body: Vehicle Damage Warnings CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 5132 Throttle Body: Description and Operation Throttle Body Housing The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 5133 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned. 1. Remove the air cleaner outlet tube. 2. Disconnect the accelerator cable and bracket. For additional information, refer to Throttle Cable/Linkage. 3. Disconnect the Throttle Position (TP) sensor electrical connector. 4. Remove the throttle body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Cable Bracket To Coil Bracket Nut 8 - 10 Nm Accelerator Cable Bracket Stud Bolt 16 - 24 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5137 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5138 Throttle Cable/Linkage: Description and Operation The accelerator cable is controlled by an accelerator pedal and shaft. The pedal and shaft should travel smoothly from the idle to wide-open throttle positions. Failure to return or hesitation on return to the idle position must not occur. Surrounding components such as wiring, hoses, sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. The speed control speedometer cable and the accelerator cable are attached at the throttle lever on the throttle body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview NOTE: Care should be exercised when performing service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause bending. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5141 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable Throttle Cable/Linkage: Service and Repair Cable REMOVAL 1. Remove the bolt and the accelerator control splash shield. 2. Disconnect the accelerator cable from the throttle body. 3. Separate the (B) accelerator cable from the (A) speed control actuator cable. 4. Disconnect the accelerator cable from the accelerator pedal and shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 5144 5. Collapse the clips at the dash panel and push the accelerator cable through the dash panel into the engine compartment and remove the accelerator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 5145 Throttle Cable/Linkage: Service and Repair Cable Bracket REMOVAL 1. Loosen the engine air cleaner outlet tube clamp and remove the air cleaner outlet tube. 2. Disconnect the PCV vent hose. 3. Disconnect the Idle Air Control (IAC) valve electrical connector. 4. Remove the bolt and the accelerator control splash shield. 5. Disconnect the accelerator cable from the throttle body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 5146 6. Remove the nut from the ignition coil bracket. 7. Remove the nut from the throttle body. 8. Remove the accelerator cable bracket. 1 Remove the bolt. 2 Remove the accelerator cable bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 5147 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5151 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5152 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5153 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation Variable Induction Control Valve: Description and Operation Intake Manifold Tuning (IMT) Valve Intake Manifold Tuning Valve (IMTV) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 5158 Intake Air System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 5159 2.5L Cougar Intake Air System 3.0L LS6 Intake Air System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 5160 3.8L Windstar Intake Air System Intake Air System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 5161 4.6L E/F-Series Intake Air System 5.4L (4V) Intake Air System The Intake Manifold Tuning (IMT) valve is a motorized actuated unit mounted directly to the intake manifold. The IMT valve actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 5162 The IMT valve motorized unit will not be energized below approximately 2600 rpm or higher on some vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The motorized unit will be commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position and then falling to approximately 50 percent to continue to hold the shutter open. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMT valve system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. 2. The PCM uses the information from the input signals to control the IMT valve. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5179 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5180 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5181 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5182 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5183 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5184 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5185 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5186 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5187 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5188 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5189 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5190 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5191 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5197 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5198 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5199 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5201 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5202 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5203 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5204 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5205 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5206 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5207 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5208 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5209 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5210 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5211 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5212 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5213 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 5216 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 5217 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5221 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5222 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 5225 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 5226 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5235 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5236 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5237 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5238 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5239 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5240 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5241 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5242 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5243 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5244 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5245 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5246 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5247 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5253 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5254 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5255 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5256 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5257 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5258 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5259 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5260 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5261 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5262 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5263 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5264 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5265 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions > Page 5269 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ The spark plug wires must be connected correctly. Mark the spark plug wires before removing them from the spark plugs. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Do not use special tool on spark plug wire boots with metal heat shields. Damage to the spark plug wire boots may occur. 1. Use the special tool to pull the spark plug wire off the spark plug with a twisting motion. 2. Squeeze the locking tab and twist while pulling upward to remove the spark plug wires from the ignition coils. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions > Page 5270 1. Connect the spark plug wires to the ignition coils. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of spark plug and ignition coil boots of the spark plug wire. 2. Install the LH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions > Page 5271 3. Install the RH spark plug wire. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Mechanical Specifications Ignition Coil: Mechanical Specifications Ignition Coil Bolts 6 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5276 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5277 Ignition Coil: Service Precautions CAUTION: ^ The spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil On Plug (COP) Ignition Coil: Description and Operation Coil On Plug (COP) Coil On Plug Coil On Plug The Coil On Plug (COP) ignition operates similar to standard coil pack ignition except each plug has one coil per plug. COP has three different modes of operation: engine crank, engine running, and CMP Failure Mode Effects Management (FMEM). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil On Plug (COP) > Page 5280 Ignition Coil: Description and Operation Coil Pack Coil Pack Horizontal Connector Six Tower Coil Pack Series 5 Six Tower Coil Pack Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil On Plug (COP) > Page 5281 Four - Tower Coil Packs Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil On Plug (COP) > Page 5282 Series 5 Four Tower Coil Pack Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six tower models. Two adjacent coil towers share a common coil and are called a matched pair. For six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4 (Figure 56)and (Figure 57). For four-tower coil pack (four cylinder) applications the matched pairs are 1 and 4, and 2 and 3 (Figure 58) and (Figure 59). When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the situation is reversed. The next pair of spark plugs fire according to the engine firing order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Page 5283 Ignition Coil: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the ignition coil electrical connections. 1 Squeeze the locking tab and twist while pulling upward to disconnect the eight spark plug wires. 2 Disconnect the radio ignition interference capacitor electrical connector. 3 Disconnect the two ignition coil electrical connectors. CAUTION: ^ The spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 3. Remove the ignition coils. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire ignition coil boots. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5287 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5297 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5298 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5299 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5301 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5302 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5303 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5304 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5305 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5306 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5307 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5308 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5309 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5315 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5316 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5317 DISCLAIMER Service Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5318 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5319 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5320 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5321 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5322 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5323 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5324 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5325 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5326 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5327 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5328 Camshaft Position Sensor: Specifications Camshaft Position Synchronizer Bolt 19 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5329 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5330 Camshaft Position Sensor: Service Precautions CAUTION: ^ Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5331 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP electrical connector. 2 Remove the screws. 3 Remove the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 5334 Camshaft Position Sensor: Service and Repair Synchronizer Syncro Positioning Tool SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: Once the engine is aligned at TDC, do not move the crankshaft until the entire procedure is complete. Doing so will result in the fuel system being out of time with the engine, causing a possible emissions fault. NOTE: Prior to the removal of the Camshaft Position (CMP) sensor, set the No.1 cylinder to Top Dead Center (TDC) of the compression stroke. Then note the position of the CMP sensor electrical connector. Installation procedures require that the electrical connector be located in the same position. 1. Remove the camshaft position (CMP) sensor. 2. Remove the (A) bolt and (B) clamp. 3. Remove the camshaft synchronizer. NOTE: The oil pump driveshaft might come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. INSTALLATION CAUTION: ^ A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. ^ It is very important to coat the gear on the camshaft synchronizer with Super Premium SAE-5W-30 Motor Oil XO-5W30-DSP or equivalent meeting Ford specification WSS-M2C153-G. Failure to do so could result in gear failure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor > Page 5335 1. Install (A) Synchro Positioning Tool, aligning tabs and notches with those on the (B) camshaft synchronizer. 2. Install the camshaft synchronizer. NOTE: ^ When installing the camshaft synchronizer into the cylinder block, make sure that the arrow on special tool is pointing toward the front of the vehicle, on a line that is parallel to the center line of the crankshaft. ^ The synchronizer will rotate slightly as the synchronizer gear engages the camshaft gear. When the synchronizer is fully installed the arrow on the special tool should point to the position of the electrical connector. 3. Position the clamp and install the bolt. 4. Remove the special tool. 5. Install the CMP sensor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5339 Crankshaft Position Sensor: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5340 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 5343 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 5344 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5350 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5351 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5352 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5353 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5354 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5357 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5358 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5359 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5363 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 5368 Spark Plug: Specifications Spark plug gap 1.3 - 1.4 mm RH Original Spark Plug AWSF32EG LH Original Spark Plug AWSF32E New Spark Plug (Either Side) AWSF32EE Spark Plugs 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5369 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. ............................................................. AWSF32EG LH Original Spark Plug Type ............................ ................................................................................................................................................... AWSF32E New Spark Plug Type (Either Side) ................................................................................... ................................................................................ AWSF32EE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5370 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 1. Shift solenoid A & B. 2. Torque Converter Clutch solenoid 3. Electronic Pressure Control Solenoid. 4. Bulkhead inter-connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5394 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5395 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5396 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. 1. Remove the bolt and EPC solenoid bracket. 2. Remove the EPC solenoid. Installation 1. Install the EPC solenoid. 1. Install the EPC solenoid. 2. Install the EPC solenoid bracket and bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5397 2. Inspect the lead frame for damage. - Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. - If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. - Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5398 through the connector slots. - Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. - Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4. Install the manual control lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5402 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5423 Shift Solenoid: Description and Operation Shift Solenoid SSA, SSB Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5427 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5445 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Transfer case shift motor bolts .............................................................................................................................................................. 10 Nm (89 inch lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5450 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions Transfer Case Actuator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 Transfer Case Actuator: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5468 Transfer Case Actuator: Service and Repair Removal and Installation 1. With the vehicle in the NEUTRAL position, raise and support the vehicle. 2. Remove the heat shield. 3. Disconnect the electrical connector. 4. Remove the coil wire from the electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5469 1. Remove the connector interlock. 2. Remove the coil wire pin. - Use the proper electrical connector pin remover. 5. Remove the rear output shaft speed sensor. - Carefully remove the sensor from the transfer case. 6. Remove the four bolts and the transfer case shift motor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5470 7. Remove the front output shaft speed sensor. - Carefully remove the sensor from transfer case. 8. NOTE: Make sure the motor mounting surfaces are clean. Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case. 9. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 5476 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 5480 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5511 Control Module: Description and Operation The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake depressed and the transmission must be in NEUTRAL. The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect the speed of the front and rear driveshafts. This input is used by the generic electronic module (GEM) primarily to control A4WD operation. The throttle position output signal is provided to the GEM from the powertrain control module (PCM). This signal is used by the GEM in controlling the A4WD clutch. The shift motor sense plate an integral part of the electric shift motor informs the GEM to the position of the transfer case. The digital TR sensors are located on the LH side of the transmission; these sensors inform the GEM when the transmission is in the neutral position. The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the HIGH range (A4WD 4HIGH) and LOW range positions. The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes. The solid state clutch relay is used to activate the A4WD clutch within the transfer case. System Function Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of time the clutch is turned on) which allows for the slight difference between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions the GEM will increase the duty cycle in order to prevent or control slip: ^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position). Feature inputs: ^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch (manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^ Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate position inputs A B C D. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4 shift motor relay outputs. Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature inputs: ^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD mode switch. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5512 ^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated). When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h (3 mph) the brake is applied and the transmission is in NEUTRAL. Feature inputs: ^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^ Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage when brake is depressed open circuit when not activated). ^ Digital transmission range sensor (ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input (manual transmission only). Feature outputs: ^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on baftery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5513 Control Module: Service and Repair AUTOMATIC FOUR WHEEL DRIVE (A4WD) Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives Throttle Position Information From the PCM Only. Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Depower the supplemental restraint system (SRS). 2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc 3. Remove the center instrument panel finish panel. 1. Remove the screws. 2. Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the GEM/CTM. 1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. 2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 Four Wheel Drive Selector Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5542 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5543 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5544 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5545 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5546 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5547 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 5556 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 5557 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T MIL Flashing, DTC'S P0741 And P1728 Set > Page 5563 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T MIL Flashing, DTC'S P0741 And P1728 Set > Page 5564 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5565 Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5566 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission > Page 5569 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 5572 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 5573 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5594 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermistor. It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 5599 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 5602 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 5605 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 5606 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch > Page 5612 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Four Wheel Drive Selector Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Description and Operation Rotary 4X4 Mode Switch 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch > Page 5631 Four Wheel Drive Selector Switch: Description and Operation Push Button 4X4 Mode Switch Switch, Push Button 4x4 Mode The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the instrument cluster push button, will illuminate only when the 4x4 Low position is engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Service and Repair Rotary 4X4 Mode Switch Mode Select Switch (MSS) Removal and Installation 1. Remove the Mode Select Switch (MSS) knob. 2. Remove the audio unit. 3. Remove the screws and pull the instrument panel center finish panel out of the instrument panel. 4. Disconnect the harness connector, remove the two screws and the MSS. 5. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 5634 Four Wheel Drive Selector Switch: Service and Repair Push Button 4X4 Mode Switch Removal and Installation 1. Remove and reposition the center instrument panel finish panel. 2. Disconnect the 4x4 mode switch electrical connector. 3. Remove the 4x4 mode switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 5635 4. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V395000 > Nov > 00 > Recall 00V395000: PCM Allows Excessive Speed PROM - Programmable Read Only Memory: Recalls Recall 00V395000: PCM Allows Excessive Speed Sport utility vehicles equipped with the 3.27 or 3.55 axle ration. The subject vehicles have a Powertrain Control Module that could allow the vehicle to exceed the design intent top speed. At these extreme speeds, the vehicle could be capable of exceeding the speed rating of the tire. Operating the vehicle above the maximum speed rating could lead to a tire failure which at these speeds could result in a crash. Dealers will reprogram the Powertrain Control Module. Owner notification is expected to begin during December 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5649 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5650 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > NHTSA00V395000 > Nov > 00 > Recall 00V395000: PCM Allows Excessive Speed PROM - Programmable Read Only Memory: All Technical Service Bulletins Recall 00V395000: PCM Allows Excessive Speed Sport utility vehicles equipped with the 3.27 or 3.55 axle ration. The subject vehicles have a Powertrain Control Module that could allow the vehicle to exceed the design intent top speed. At these extreme speeds, the vehicle could be capable of exceeding the speed rating of the tire. Operating the vehicle above the maximum speed rating could lead to a tire failure which at these speeds could result in a crash. Dealers will reprogram the Powertrain Control Module. Owner notification is expected to begin during December 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5660 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5661 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 1. Shift solenoid A & B. 2. Torque Converter Clutch solenoid 3. Electronic Pressure Control Solenoid. 4. Bulkhead inter-connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5685 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5686 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5687 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. 1. Remove the bolt and EPC solenoid bracket. 2. Remove the EPC solenoid. Installation 1. Install the EPC solenoid. 1. Install the EPC solenoid. 2. Install the EPC solenoid bracket and bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5688 2. Inspect the lead frame for damage. - Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. - If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. - Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5689 through the connector slots. - Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. - Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4. Install the manual control lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5693 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5714 Shift Solenoid: Description and Operation Shift Solenoid SSA, SSB Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5718 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5736 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Transfer case shift motor bolts .............................................................................................................................................................. 10 Nm (89 inch lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5741 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions Transfer Case Actuator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Transfer Case Actuator: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5759 Transfer Case Actuator: Service and Repair Removal and Installation 1. With the vehicle in the NEUTRAL position, raise and support the vehicle. 2. Remove the heat shield. 3. Disconnect the electrical connector. 4. Remove the coil wire from the electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5760 1. Remove the connector interlock. 2. Remove the coil wire pin. - Use the proper electrical connector pin remover. 5. Remove the rear output shaft speed sensor. - Carefully remove the sensor from the transfer case. 6. Remove the four bolts and the transfer case shift motor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5761 7. Remove the front output shaft speed sensor. - Carefully remove the sensor from transfer case. 8. NOTE: Make sure the motor mounting surfaces are clean. Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case. 9. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 1. Shift solenoid A & B. 2. Torque Converter Clutch solenoid 3. Electronic Pressure Control Solenoid. 4. Bulkhead inter-connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5784 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5785 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5786 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. 1. Remove the bolt and EPC solenoid bracket. 2. Remove the EPC solenoid. Installation 1. Install the EPC solenoid. 1. Install the EPC solenoid. 2. Install the EPC solenoid bracket and bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5787 2. Inspect the lead frame for damage. - Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. - If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. - Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5788 through the connector slots. - Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. - Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4. Install the manual control lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5792 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5813 Shift Solenoid: Description and Operation Shift Solenoid SSA, SSB Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5817 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5835 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications > 1-2 Accumulator Accumulator: Specifications 1-2 Accumulator Special Tools Removal 1. Using the special tool, compress the 1-2 accumulator cover and remove the accumulator piston retaining ring. 2. Note: Note the location of the 1-2 accumulator springs for reference during assembly. Remove the 1-2 accumulator. 1. Remove the 1-2 accumulator cover. 2. Remove the lower 1-2 accumulator spring. 3. Remove the accumulator piston. 4. +Remove the upper 1-2 accumulator spring. Installation 1. Install the 1-2 accumulator. 1. Install the 1-2 accumulator upper spring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications > 1-2 Accumulator > Page 5840 2. Install the accumulator piston. 3. Install the 1-2 accumulator lower spring. 4. Install the cover and seal assembly. 2. Using the special tool, install the accumulator piston retaining ring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications > 1-2 Accumulator > Page 5841 Accumulator: Specifications 2-3 Accumulator Removal 1. Remove the main control valve body. 2. Remove the 2-3 accumulator piston retainer. 3. Remove the accumulator piston and spring. Installation 1. Install the 2-3 accumulator assembly. 1. Install the accumulator piston. 2. Install the accumulator piston spring. 3. Install the accumulator spring retainer. 2. Install the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo Band Apply Servo: Service and Repair Overdrive Servo Special Tools Removal 1. Remove the main control valve body. 2. CAUTION: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on overdrive servo internal retaining ring. Using the special tool, compress the servo spring then remove the overdrive servo retaining ring. 3. Remove the (A) overdrive servo piston and the (B) overdrive servo piston return spring. Installation 1. Install the overdrive servo piston assembly. 1. Install the overdrive servo piston return spring. 2. Install the overdrive servo piston assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 5846 2. Using the special tool, install the overdrive servo piston retaining ring. 3. Install the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 5847 Band Apply Servo: Service and Repair Reverse Servo Assembly Special Tools Removal 1. Remove the main control valve body. 2. Use the Servo Piston Remover/Replacer to remove the reverse band servo retaining ring. 1. Compress the servo spring. 2. Remove the reverse band servo retaining ring. 3. Note: The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed. Remove the (A) reverse band servo cover, (B) reverse band servo piston and rod and (C) reverse band servo spring. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 5848 Note: This is not an ordinary installation procedure and does not compensate for band wear. 1. Note: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal. Install the reverse servo piston and return spring. Do not install the piston cover. 2. Install the Servo Piston Selection Tool and tighten the band apply bolt. 3. Attach the Dial Indicator With Bracketry. - Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. 4. Loosen the bolt until the piston stops against the tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 5849 5. Verify the amount of piston travel on the dial indicator is within specification. 6. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two groove or (C) three groove, to bring the servo piston travel within specification. 7. Remove the dial indicator and servo selection tool. 8. Install the proper servo piston assembly spring and the reverse servo piston cover and seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Servo > Page 5850 9. Use the Servo Piston Remover/Replacer to install the reverse servo retaining ring. 1. Compress the servo spring. 2. Install the reverse band servo retaining ring. 10. Install the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch Clutch: Specifications Direct Clutch Clearance mm (inch) ............................................................................................................................................................. 1.5748-2.159 (0.062-0.085) Snap Ring Thickness mm (inch) .............................................................................................................................................................. ............................ 1.270-1.372 (0.050-0.054) ...................................................................................... .................................................................................................... 1.625-1.727 (0.064-0.068) .............. .............................................................................................................................................................. .............. 1.981-2.083 (0.078-0.082) .................................................................................................... ..................................................................................... 2.337-2.43X (0.092-0.096) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 5855 Clutch: Specifications Forward Clutch Forward Clutch Pack Clearance mm (inch) ........................................................................................................................... ........................................ 1.17-1.63 (0.046-0.068) Snap Ring Thickness mm (inch) .............................................................................................................................................................. ............................ 1.524-1.625 (0.060-0.064) ...................................................................................... .................................................................................................... 1.880-1.981 (0.074-0.078) .............. .............................................................................................................................................................. .............. 2.235-2.337 (0.088-0.092) .................................................................................................... ...................................................................................... 2.591-2.692 (0.102-0.106) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 5856 Clutch: Specifications Intermediate Clutch Clearance mm (inch) ....................................................................................................................................................... 41.7322-42.5958 (1.643-1.677) Selective Steel Plate mm (inch) .............................................................................................................................................................. ............................ 1.702-1.803 (0.067-0.071) ...................................................................................... .................................................................................................... 1.956-2.057 (0.077-0.081) .............. .............................................................................................................................................................. .............. 2.210-2.311 (0.087-0.091) .................................................................................................... ...................................................................................... 2.464-2.565 (0.097-0.101) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 5857 Clutch: Specifications Reverse Clutch Clearance mm (inch) ........................................................................................................................... ........................................ 1.27-1.94 (0.050-0.076) Snap Ring Thickness mm (inch) .............................................................................................................................................................. ............................ 1.524-1.625 (0.060-0.064) ...................................................................................... .................................................................................................... 1.880-1.981 (0.074-0.078) .............. .............................................................................................................................................................. .............. 2.235-2.337 (0.088-0.032) .................................................................................................... ...................................................................................... 2.591-2.692 (0.102-0.106) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension Housing Bolts 19 - 22 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Refill Capacity ............................................................................................................... ..................................................................... 13.9 Qt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5868 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5869 Fluid - A/T: Service and Repair Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5870 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5871 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5872 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair. At this time, the torque converter, transmission cooler and tubes must be thoroughly flushed to remove any dirt. The transmission fluid needs to be changed if evidence of fluid contamination is found. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. 2. CAUTION: Use of a fluid other than specified could result in transmission failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level. Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 5876 7. Remove torque converter housing plug. 8. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler tubes. Installation 1. Note: A new torque converter drain plug must be used. Install the torque converter drain plug. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 5877 2. Install torque converter housing plug. 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. Note: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. Note: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 5878 6. Install bolts. 7. Lower the vehicle. 8. Note: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable. 9. Note: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(r) V. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Fluid Cooler Line Case Fittings 15 - 19 ft.lb Cooler Tube Nut to Case Fitting 13 ft.lb Transmission Auxiliary Fluid Cooler Hose Clamps 27 - 35 in.lb Transmission Fluid Cooler Tube Fitting To Radiator 10 - 16 ft.lb Transmission Fluid Cooler Tube Fittings At Case 21 - 25 ft.lb Transmission Cooler Lines Bracket Bolts 28 - 38 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5882 Fluid Line/Hose: Service and Repair Removal 1. WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the radiator air deflector. 1. Remove the bolts. 2. Remove the radiator air deflector. 3. Remove the nut, bolt, and transmission cooler line bracket. 4. Remove the transmission fluid cooler tubes. 1. Remove the clips. 2. Disconnect the fittings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5883 - Use a backup wrench to hold the case fitting secure. 3. Remove the nut. 4. Remove the transmission fluid cooler tubes. Installation 1. Note: When a transmission fluid cooler tube is replaced, each replacement tube must be fabricated from the same size tube as the original. Shape a new transmission fluid cooler tube. Use the prior tube as a guide. - Install the appropriate fittings. - Use a double flare on the ends of the tubes. CAUTION: To prevent damage, make sure all plugs are removed from port openings before installing tubes. CAUTION: To prevent cross threading, all tube nuts must be hand started before being torqued to specification. 2. Install the transmission fluid cooler tubes. 1. Install the clips. 2. Connect the tube fittings to the radiator. 3. Connect the tube fitting to the transmission. - Use a backup wrench to hold the case fitting secure. 4. Install the tube bracket nut. 5. Install the transmission fluid cooler tubes. 3. Install the transmission cooler line bracket and nut and bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5884 4. Install the radiator air deflector. - Install the bolts. 5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill transmission fluid to the proper level using the correct fluid and inspect for leaks. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility Fluid Pan: Technical Service Bulletins A/T - 5R44E/5R55E Part Level Change/Compatibility TSB 06-24-13 11/20/06 5R44E / 5R55E SERVICE PART LEVEL CHANGE / COMPATIBILITY FORD: 1997 Aerostar 1997-2001 Explorer 1997-2007 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac MERCURY: 1998-2001 Mountaineer ISSUE Some vehicles equipped with a 5R44E or 5R55E automatic transmission may require repair of the transmission. This TSB is being published as informational only in order to avoid mix I match of incorrect service parts which will cause a fluid leak. Beginning with 8/29/2006 production, the 5R44E or 5R55E automatic transmission will have a new transmission case, fluid pan, a REUSABLE fluid pan gasket and new fluid pan screws. ACTION Follow the Service Tips. SERVICE TIPS NOTE DO NOT MIX AND MATCH PARTS OR LEAKAGE WILL OCCUR. NOTE THE NEW PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The 5R44E / 5R55E transmission pan gasket has been redesigned to be reusable if it is removed for a non-leak related transmission service concern. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. The case and fluid pan rails have been redesigned to properly mate with the new gasket to eliminate fluid leaks. The new case, pan, and gasket maybe used to service past model transmissions from 1997. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5889 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5890 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5891 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5892 For 1997-2007 (early production) 4R44E I 5R44E and 5R55E when servicing the fluid pan gasket (7A191), the fluid pan (7A194) or the case (7005) do not mix and match old level and new level parts. The old level gasket, refer to Figure 3 (7A191) will be continued for past model applications. If replacing the older design level case, refer to Figure 1 (7005) and/or old lever fluid pan, refer to Figure 2 (7A194), ALL new components must be used. This includes the case (7005), refer to Figure 4, fluid pan (7A194), refer to Figure 5, fluid pan gasket (7A191), refer to Figure 6 and pan screws (W500212) (new torque specification - 7 lb-ft (10 N.m) refer to Figure 7. For correct part numbers refer to your parts catalogue. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5893 Fluid Pan: Specifications Transmission Fluid Pan Bolts 9 - 11 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5894 Fluid Pan: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair. At this time, the torque converter, transmission cooler and tubes must be thoroughly flushed to remove any dirt. The transmission fluid needs to be changed if evidence of fluid contamination is found. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. 2. CAUTION: Use of a fluid other than specified could result in transmission failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level. Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5895 7. Remove torque converter housing plug. 8. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 9. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler tubes. Installation 1. Note: A new torque converter drain plug must be used. Install the torque converter drain plug. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5896 2. Install torque converter housing plug. 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. Note: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. Note: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1. Position transmission fluid pan gasket. 2. Position the transmission fluid pan. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5897 6. Install bolts. 7. Lower the vehicle. 8. Note: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable. 9. Note: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(r) V. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Front Pump Bolts 15 - 19 ft.lb Front Pump Support Bolts 15 - 19 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 5905 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 5909 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations > Page 5913 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: Customer Interest A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5922 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5923 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5924 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5930 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5931 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5932 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 1. Shift solenoid A & B. 2. Torque Converter Clutch solenoid 3. Electronic Pressure Control Solenoid. 4. Bulkhead inter-connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5953 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5954 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5955 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. 1. Remove the bolt and EPC solenoid bracket. 2. Remove the EPC solenoid. Installation 1. Install the EPC solenoid. 1. Install the EPC solenoid. 2. Install the EPC solenoid bracket and bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5956 2. Inspect the lead frame for damage. - Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. - If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. - Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5957 through the connector slots. - Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. - Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4. Install the manual control lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T Seals and Gaskets: Service and Repair Extension Housing Seal, A/T Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Drain the transmission fluid. 4. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions. Remove the rear driveshaft. 1. Remove the four bolts. 2. Remove the rear driveshaft. 5. Use High-Lift Jack to support the transmission. 6. Remove the nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5966 7. Remove the bolts. 8. Remove the transmission crossmember. 1. Remove the bolts. 2. Remove the transmission crossmember. 9. Lower the transmission to access the extension housing bolts. 10. Use (A) Seal Remover and (B) Impact Slide Hammer to remove the (C) extension housing seal. 11. Remove the extension housing and gasket. 1. Remove the bolts and nuts. 2. Remove the extension housing and gasket. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5967 1. Install the extension housing and gasket. 1. Position the extension housing gasket and the extension housing. 2. Install the bolts and nuts. 2. Install the new extension housing seal. 1. Align Extension Housing Seal Replacer with the seal. 2. Install the extension housing seal. 3. Raise and position the transmission. 4. Install the transmission crossmember. 1. Position the transmission crossmember. 2. Install the bolts. 5. Install the transmission crossmember bolts. 6. Remove High-Lift Jack. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5968 7. Install the nuts. 8. Lower the vehicle. 9. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5969 Seals and Gaskets: Service and Repair Shift Shaft Seal Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. On 4x4 vehicles, remove the front driveshaft. 1. Remove the eight front driveshaft bolts (four each end). 2. Remove the front driveshaft. 4. Drain the transmission fluid and remove the fluid pan and filter. 5. Disconnect digital TR sensor electrical connector. 6. Disconnect the transmission shift linkage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5970 7. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the outer manual control lever shaft nut. 2. Remove the manual control lever. 8. Remove the digital transmission range TR sensor. 1. Remove the two bolts. 2. Remove the digital TR sensor. 9. Remove the manual control valve detent lever spring 1. Remove the bolt. 2. Remove the manual control valve detent lever spring. 10. Note: Use a shop cloth to protect the transmission case surface. Remove the manual lever shaft retaining pin. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5971 11. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of the case. 12. Remove the parking lever actuating rod. 1. Remove the manual valve detent lever. 2. Remove the parking lever actuating rod. 13. CAUTION: Use care not to damage the manual control lever shaft bore. New seal may leak. Remove the manual control lever shaft seal. Installation 1. Use (A) Shift Lever Seal Replacer to install the (B) manual control lever seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5972 2. Install the parking lever actuating rod. 1. Install the parking lever actuating rod. 2. Install the manual valve detent lever. 3. Install the manual control lever shaft. 1. Install the manual control lever shaft. 2. Install the inner manual control lever shaft nut. 3. Install the manual lever shaft retaining pin. 4. Install the manual valve detent lever spring. 1. Position the manual valve detent lever spring. 2. Install the manual valve detent lever spring bolt. 5. Install the digital TR sensor. 1. Install the digital TR sensor. 2. Loosely install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5973 6. Note: Manual shift lever must be in the neutral position. Use Digital Transmission Range (TR) Sensor Alignment Tool to align the digital TR sensor slots. 7. Tighten the bolts. 8. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. 9. With manual lever in overdrive, connect the shift control cable. 10. Install digital TR sensor electrical connector. 11. Install the filter and transmission fluid pan. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5974 12. On 4x4 vehicles, install the front driveshaft. 1. Position the front driveshaft. 2. Install the eight front driveshaft bolts (four each end). 13. Lower the vehicle. 14. Connect the battery ground cable. 15. Fill the transmission with fluid and inspect for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5982 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5983 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5984 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5985 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5986 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5987 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 5996 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 5997 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6003 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6004 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 6005 Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 6006 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission > Page 6009 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6012 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6013 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6034 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermistor. It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 6039 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 6060 Shift Solenoid: Description and Operation Shift Solenoid SSA, SSB Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair Removal 1. Remove the ignition switch. 2. Remove the upper steering column shroud. 3. Remove the gearshift lever. 1. Disconnect the shift control selector lever harness connector. 2. Remove and discard the gearshift lever pin. 3. Remove the gearshift lever. Installation 1. Note: The gearshift lever pin must be replaced whenever removed. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications Selector Shaft: Specifications Manual Lever Shaft Nut 20-27 ft.lb Manual Lever Shaft Outer Nut 23-25 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Shift Cable Bracket 15-21 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 6071 Shift Cable: Adjustments 1. Place the gearshift lever in the (D) position and hang a 3.6 kg (8 lb.) weight on the gearshift lever. 2. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual control lever. 4. Pull out the transmission shift cable adjustment lock tab on the shift cable body. 5. Place the manual control lever in the (D) position. 1. Place the manual control lever in the first gear position. Rotate the manual control lever forward until travel stops. 2. Move the manual control lever back two detents to the (D) position. 6. Connect the transmission shift cable to the manual control lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 6072 7. Push in the transmission shift cable adjustment lock tab on the shift cable body. 8. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 9. Remove the 3.6 kg (8 lb.) weight. 10. CAUTION: Do not adjust the transmission shift cable in any position other than (D). Verify that the vehicle will start in P or N and that backup lamps illuminate in R. If not, repeat Steps 1 through 7 and perform a digital transmission range sensor alignment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 6073 Shift Cable: Service and Repair Removal 1. Disconnect the transmission shift cable from the steering column. 1. Disconnect the shift cable from the transmission column shift selector tube. 2. Disconnect the shift cable from the steering column bracket. 2. Push the rubber grommet and shift cable through the bulkhead. 3. Raise and support the vehicle. 4. Remove the transmission shift cable from the transmission. 1. Disconnect the shift cable from the manual control lever. 2. Depress the lock tabs to release the shift cable and disconnect the shift cable from the shift cable bracket. 5. Remove the transmission shift cable bracket from the automatic transmission. 1. Remove the bolts. 2. Remove the transmission shift cable bracket. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 6074 1. Follow the removal procedure in reverse order. - Adjust the transmission shift cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Stall Speed Mini 2481 Max 2904 End Play New or Rebuilt 0.014 - 0.041 in Used 0.014 - 0.074 in Torque Converter Drain Plug 21 - 22 ft.lb Torque Converter Nuts 20 - 33 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6081 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6099 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6108 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6109 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6110 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 6116 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 6117 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator Transmission Cooler: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator > Page 6122 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator > Page 6123 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator > Page 6124 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6130 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6131 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6132 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6133 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6134 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6140 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6141 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6142 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6143 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6144 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 6145 Transmission Cooler: Specifications Transmission Auxiliary Fluid Cooler Bolts 45 - 62 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 6146 Transmission Cooler: Service and Repair Removal 1. Shut off the air suspension if equipped. 2. Disconnect the battery cables. 3. Raise and support the vehicle. 4. Remove the radiator air deflector. 1. Remove the bolts. 2. Remove the radiator air deflector. 5. Place a drain pan under the transmission auxiliary fluid cooler. 6. Note: On 5.0L, the radiator must be loosened to provide access for removing the upper transmission fluid cooler screw. Loosen the two upper radiator hold down screws. 7. Remove the transmission auxiliary fluid cooler. 1. Disconnect the hoses. 2. Remove the bolts. 3. Remove the transmission auxiliary fluid cooler. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 6147 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Transmission Mount Nuts 25 - 34 ft.lb Transmission Mount Bolts 50 - 68 ft.lb Rear Insulator Bolts 58 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 6154 Transmission Mount: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Use High Lift Transmission Jack to support the transmission and remove the nuts. 4. Raise the transmission enough for studs to clear the crossmember. 1. Remove the bolts. 2. Remove the transmission insulator. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6158 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6159 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6160 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6161 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6162 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6163 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6172 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6173 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6179 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6180 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6186 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6187 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6188 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6194 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6195 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6196 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 6197 Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 6198 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission > Page 6201 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6204 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6205 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6226 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermistor. It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: Customer Interest A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6235 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6236 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: All Technical Service Bulletins A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6242 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6243 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6244 Valve Body: Specifications Main Control Valve Body Bolts 80 - 97 in.lb Main Control Valve Body Cover Plate Bolts 80 - 97 in.lb Main Control Valve Body Separator Plate Bolts 80 - 97 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6245 Valve Body: Diagrams MAIN CONTROL VALVE BODY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6246 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly Valve Body: Service and Repair Disassembly and Assembly MAIN CONTROL VALVE BODY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6249 Disassembly Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6250 1. Remove the torque converter clutch (TCC) solenoid and the shift solenoid. 1. Remove the bolt. 2. Remove the shift solenoid. Remove the TCC solenoid. 2. Remove the three reinforcement plates. 1. Remove the bolts. 2. Remove the plates. 3. Remove the separator plate and discard the gaskets. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6251 4. Note: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the eight coasting booster valve shuttle balls. 5. Remove the converter drain back valve and solenoid pressure supply screen. 6. Remove the main control valve body cover plate. 1. Remove the 13 bolts. 2. Remove the valve body cover plate and gasket Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6252 Assembly 1. CAUTION: Before beginning assembly, carry out and inspect the following: When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals. All fasteners must be tightened to the torque specification indicated. The necessary torques can be found in Specifications. When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly. Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces. Install the valve body cover plate. 1. Position the valve body cover plate gasket and cover plate. 2. Install the two guide pin bolts. 3. Install the bolts. 2. Tighten the bolts in the sequence shown. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6253 3. Install the eight coasting booster valve shuttle balls. 4. Install the converter drain back valve and solenoid pressure supply screen. 5. Install the separator plate and gaskets. 6. Install the three reinforcement plates. 1. Position the plates. 2. Install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6254 7. Note: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. Install the shift solenoid. 1. Position the TCC solenoid. 2. Position the shift solenoid. 3. Install the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6255 Valve Body: Service and Repair Removal and Installation Removal 1. Drain transmission fluid and remove the transmission fluid pan and filter. 2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the shift solenoid and the TCC solenoid. 1. Remove the bolts. 2. Remove the shift solenoid and the TCC solenoid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6256 4. Remove the manual control valve detent lever spring. 1. Remove the bolt. 2. Remove the manual control valve detent Lever spring. 5. Remove the 23 valve body to case bolts. 6. Remove the main control valve body and discard the pump outlet screen. Installation 1. Note: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the proper location prior to installing the bolts. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6257 2. Note: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 3. Note: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 4. Install the manual control valve detent lever spring. 1. Position the manual control valve detent lever spring. 2. Install the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6258 5. Tighten the main control valve body bolts in the sequence shown. 6. Install the shift solenoid and the TCC solenoid. 1. Install the shift solenoid and the TCC solenoid. 2. Install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6259 7. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the EPC solenoid. - Connect the TCC. - Connect the shift solenoid SSA and SSB. 8. CAUTION: If installing a new filter, and the grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore. Note: If transmission is being repaired liar a contamination-related failure, use a new filter and seal. Replace fluid filter and seal as required. 9. Position the (B) pan magnet into the (A) transmission fluid pan. 10. Note: The pan gasket is reusable. Clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 6260 11. Install the bolts. 12. Fill the transmission with fluid and check for proper operation. 13. Install the filter and pan. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications O.S. Diameter (approx.) 10.2 in I.S. Diameter (approx.) 7.3 in Facing Area Sq. cm (sq. in) 508 (787) Compressed Thickness 0.307 in Lining Material Woven non-asbestos Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6265 Clutch Disc: Service and Repair Special Tools Removal 1. Remove the transmission. 2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring win occur resulting in complete clutch release. Remove the clutch pressure plate and clutch disc. 1. If the parts are to be reused, mark the clutch pressure plate and flywheel. 2. Remove the bolts. 3. Remove the clutch pressure plate and clutch disc. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6266 1. Note: Self-adjusting clutch pressure plate must be adjusted before installation. Compress the clutch diaphragm fingers. 1. Place the (A) flywheel and the (B) clutch pressure plate in a press. 2. Use a (C) suitable adapter and a (D) press to depress the (E) clutch diaphragm fingers until the adjusting ring moves freely. 2. Adjust the clutch pressure plate. - Rotate the (A) adjusting ring counterclockwise until the (B) tension springs are compressed. - Hold the (A) adjusting ring while releasing the pressure on the clutch fingers. 3. Position the (A) clutch disc on the (B) flywheel using the (C) Clutch Aligner. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6267 4. Note: If reusing the clutch pressure plate and flywheel, align the marks made during removal. Position the clutch pressure plate on three dowels. 1. Align the clutch pressure plate and install the clutch pressure plate bolts. 2. Remove Clutch Aligner. 5. Install the transmission. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid Type DOT-3 Brake Fluid Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications Clutch Master Cylinder: Specifications Clutch Master Cylinder Reservoir Bolts 16 - 23 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 6275 Clutch Master Cylinder: Service and Repair Special Tool(s) Special Tool Clutch Master Cylinder/Reservoir Removal and Installation 1. Raise and support the vehicle. 2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. 3. Lower the vehicle. 4. Disconnect the clutch pedal position (CPP) switch electrical connector. 5. Disconnect the clutch master cylinder rod from the clutch pedal arm. Remove and discard the clutch master cylinder push rod bushing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 6276 6. Remove the CPP switch. - Pinch the lock tabs and pull the clip forward. Rotate and snap the CPP switch from the clutch master cylinder rod. 7. Remove the reservoir. 8. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 9. Unclip the hydraulic line-to-frame retainer. 10. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Unlock and remove the clutch master cylinder assembly. Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket. - Remove the reservoir the hydraulic line and the clutch master cylinder as an assembly. Install a new clutch master cylinder push rod bushing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 6277 11. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. To install, reverse the removal procedure. Bleed the clutch hydraulic system. Rotate the clutch master cylinder 45 degrees counterclockwise. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Clutch Slave Cylinder Bolts 13 - 17 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 6281 Clutch Slave Cylinder: Service and Repair Removal 1. Disconnect the clutch master cylinder hydraulic line from the clutch slave cylinder with (A) Clutch Coupling Tool. 2. Remove the transmission. 3. Note: Inspect the clutch housing for traces of fluid. If fluid is visible, replace the clutch slave cylinder. Remove the clutch slave cylinder. 1. Remove the bolts. 2. Remove the clutch slave cylinder. 4. CAUTION: The clutch release hub and bearing is prelubricated and should not be cleaned with solvent. The clutch release hub and bearing are replaced as an assembly. Do not disassemble for inspection or replacement. Remove the clutch release hub and bearing from the clutch slave cylinder. 1. Push the clutch release hub and bearing against the spring and move toward the base. 2. Remove the retainer ring and remove the clutch release hub and bearing and the spring. 5. Inspect the clutch slave cylinder for the following: - Weak spring. - Leaking fluid. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 6282 1. Install the clutch release hub and bearing. - Lubricate the clutch release hub and bearing at sliding points with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 1. Position the (A) spring and the (B) clutch release hub and bearing onto the clutch slave cylinder. 2. Push the clutch release hub and bearing against the spring and install the retainer ring. 2. Install the clutch slave cylinder. 1. Position the clutch slave cylinder. 2. Install the bolts. 3. Install the transmission. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair Removal 1. Raise and support the vehicle. 2. Disconnect the line from the plastic clip at the floor flange. 3. Uncouple the lower end of the clutch master cylinder hydraulic line from the clutch slave cylinder using (A) Clutch Coupling Tool. 4. Lower the vehicle. 5. Remove the clutch master cylinder and the hydraulic line assembly. 6. Remove and discard the roll pin holding the line to the clutch master cylinder. 7. Note: Check that the O-ring is still in the outlet port of the clutch master cylinder. If not, replace. Disconnect the line from the clutch master cylinder by applying a slight tug on the line. Installation 1. Insert the new line into the clutch master cylinder outlet port. 2. Install clutch master cylinder tube. 1. Position line and install roll pin. 2. Tug on clutch master cylinder tube. 3. Raise and support the vehicle. 4. Bleed the system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 6286 5. Note: Check that the O-ring is in place on the line. Check the clutch slave cylinder port to be sure there is no O-ring. Insert the male coupling end into the female coupling of the clutch slave cylinder. Check that the connection is secure by applying a slight tug to the line. 6. Connect the line to the plastic clip on the floor flange. 7. Lower the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 6287 Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Removal 1. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface wash it immediately with water. Disconnect the clutch master cylinder push rod. 2. Remove the retainer ring. 3. Note: When the clutch pedal shaft is removed from the bracket, the brake pedal, brake and clutch pedal bushings, and spring washer become accessible. Remove the clutch pedal from the pedal support bracket. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 6291 1. Note: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the brake and clutch pedal bushings. Clean and lubricate with a light film of SAE 30 engine oil X0-30-BSD or equivalent ESE-M2C153-E and replace the brake and clutch pedal bushing if excessive wear is evident. Install the clutch/brake pedal assembly. Install the clutch/brake pedal bushings and washers and the clutch pedal. - Install the clutch pedal shaft. 2. Install the retainer ring. 3. Install the clutch master cylinder push rod to pedal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Special Tools Removal 1. Note: Only replace the transmission input shaft pilot bearing if it is damaged. Remove the transmission input shaft pilot bearing using Impact Slide Hammer and Puller. 2. Inspect the transmission input shaft pilot bearing for: - misalignment and looseness in the flywheel. - needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration. - seal leakage. 3. CAUTION: To prevent damage, do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent. Clean the clutch pressure plate using a suitable commercial alcohol-based solvent so surface is free from oil film. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 6298 1. Note: The transmission input shaft pilot bearing can only be installed with the seal facing the transmission. The transmission input shaft pilot bearing is pregreased and does not require additional lubrication. A new transmission input shaft pilot bearing must be installed whenever it is removed. Install the (A) transmission input shaft pilot bearing using (B) Pilot Bearing Replacer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch Pressure Plate Bolts 17 - 23 ft.lb Total Plate Pressure 2248-315 lbf Diaphragm Spring Belleville Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6302 Pressure Plate: Service and Repair Special Tools Removal 1. Remove the transmission. 2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring win occur resulting in complete clutch release. Remove the clutch pressure plate and clutch disc. 1. If the parts are to be reused, mark the clutch pressure plate and flywheel. 2. Remove the bolts. 3. Remove the clutch pressure plate and clutch disc. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6303 1. Note: Self-adjusting clutch pressure plate must be adjusted before installation. Compress the clutch diaphragm fingers. 1. Place the (A) flywheel and the (B) clutch pressure plate in a press. 2. Use a (C) suitable adapter and a (D) press to depress the (E) clutch diaphragm fingers until the adjusting ring moves freely. 2. Adjust the clutch pressure plate. - Rotate the (A) adjusting ring counterclockwise until the (B) tension springs are compressed. - Hold the (A) adjusting ring while releasing the pressure on the clutch fingers. 3. Position the (A) clutch disc on the (B) flywheel using the (C) Clutch Aligner. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6304 4. Note: If reusing the clutch pressure plate and flywheel, align the marks made during removal. Position the clutch pressure plate on three dowels. 1. Align the clutch pressure plate and install the clutch pressure plate bolts. 2. Remove Clutch Aligner. 5. Install the transmission. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair Carrier Bearings: Service and Repair AXLE TUBE BEARING Special Service Tool(s) Removal 1. Remove the right-hand halfshaft. 2. Remove the right-hand axle shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Page 6310 3. Use a converter oil seal remover and a slide hammer to remove the axle seal. 4. Use an axle bearing remover and a slide hammer to remove the axle tube bearing. 5. Clean the bearing and seal surfaces of any foreign debris. Installation 1. Use the Axle Bearing Replacer and the Handle to replace the RH axle tube bearing. 2. Check the bearing depth as shown. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > Page 6311 3. Use the Axle Seal Replacer and the Handle to replace the axle tube seal. 4. CAUTION: Care should be taken not to damage the axle seal surface. Install the axle shaft. 5. Refill the front drive axle to proper level using Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. 6. Install the RH halfshaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications Differential Case: Specifications Maximum differential case runout ................................................................................................................................................ 0.076 mm (0.003 inch) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front Differential Case: Service and Repair Front Special Tools Disassembly 1. Remove the differential ring gear. 1. Remove and discard the bolts. 2. Using a drift that will bottom out in the bolt holes, separate the differential ring gear from the differential case. 2. Drive out the differential pinion shaft roll pin. 3. Remove the differential pinion shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6317 4. CAUTION: The upper differential side gear may fall out of the case bore after removing the differential pinion gears. Rotate the differential pinion gears to the differential case window and remove them and the differential pinion thrust washers. 5. Remove the differential side gears and the differential side gear thrust washers. 6. Assemble the special tool. 7. Position the special tool on the differential bearing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6318 8. Using the special tool, remove the differential bearing. - Repeat the procedure for the other bearing. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gears, and assemble them. - Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. 2. Position the differential side gear and thrust washer assemblies in the differential case. 3. Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble them. - Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6319 4. Engage the differential pinion gears between the differential side gears. 5. Rotate the differential pinion gears and align them with the differential pinion shaft bore. 6. Insert the differential pinion shaft. 7. Install the differential pinion shaft roll pin. 8. install the differential bearing shims, the differential bearings, and the differential ring gear. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6320 Differential Case: Service and Repair Rear Differential Case and Ring Gear-Conventional Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 ring gear bolts. 3. CAUTION: Care should be taken not to damage the bolt hole threads. Insert a punch in the bolt holes and drive the ring gear off. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6321 4. Note: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring if required. 5. If required, use the special tools to remove the differential bearings. 6. Remove the differential pinion shaft lock bolt. 7. Remove the differential pinion shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6322 8. Rotate and remove the differential pinion gears and the differential pinion thrust washers. 9. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals. - For vehicles with 5.0L engines, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A. - For vehicles with 4.0L engines, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C197-A. - Position thee differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6323 3. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble. - For vehicles with 5.0L engines, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A. - For vehicles with 4.0L engines, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C197-A. 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align with the differential pinion shaft bore. 6. Insert the differential pinion shaft. - Align the hole in the differential pinion shaft with the hole in the differential case. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6324 7. CAUTION: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G351-A5 prior to installation. Install a new differential pinion shaft lock bolt and tighten finger-tight. 8. Using the special tool, install the new differential bearings on the differential case. 9. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 10. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 11. Install the differential case. Differential Case and Ring Gear-Traction-LOK Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6325 Special Tools Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6326 3. CAUTION: Do not damage the bolt hole threads. Insert a punch in the bolt holes, and drive the ring gear off. 4. CAUTION: Do not reuse the anti-lock speed sensor ring after removing it. If necessary, remove the anti-lock speed sensor ring and discard it. 5. Using the special tools, remove the differential bearings. 6. Remove the differential pinion shaft lock bolt, and remove the differential pinion shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6327 7. WARNING: Due to the spring tension, take care when removing the differential clutch spring. Remove the differential clutch spring. 8. Remove the differential gears and washers. 1. Remove the differential pinion gears. 2. Remove the differential side gears. 3. Remove the differential pinion thrust washers Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6328 9. CAUTION: Keep the differential clutch packs in order. Do not mix them. Be sure to reassemble them in the same sequence. Remove and tag the differential clutch packs, shims and differential side gears "right" and left". 10. CAUTION: Do not use acids or solvents to clean the differential clutch packs. Wipe the components with a clean, lint-free cloth only. Clean and inspect the differential clutch packs for wear and damage. Install new parts as necessary. 11. Clean and inspect the remaining differential case components for wear and damage. Install new components as necessary. Assembly 1. CAUTION: Use 118 ml. (4 oz.) of Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A in the axle. Prelubricate each steel clutch plate and soak all of the friction plates in Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6329 2. CAUTION: Do not mix the left and right side differential clutch packs and shims. Assemble the left and right differential clutch packs (without the shims) and differential side gears. 3. CAUTION: Use the correct mandrel with the Differential Clutch Gauge. Place the special tool in a vise. 4. Install the differential clutch pack and differential side gear (without the shim) on the special tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6330 5. Position the special tool hand-tight on top of the differential clutch pack. 6. Install the special tool over the disc and differential clutch pack. 7. Install the nut. 8. Note: Clutch Pack Kit FSAZ-4947-BA is available to rebuild the 8.8-inch ring gear Traction-Lok differential. Using the special tool, determine the thickness of the new clutch shim. Insert the thickest blade that will enter between the tool and the differential clutch pack. Selective Shims 9. Remove the special tool from the clutch pack and side gear assembly. 10. Install the shims on the clutch pack and side gear assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6331 11. Install the differential side gear assemblies in the differential case. 12. Install the differential pinion gears with the differential pinion thrust washers in the differential case. 13. Using a soft-faced hammer, install the differential clutch spring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6332 14. Install the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 15. Using the special tool, install the differential bearings. 16. Install the anti-lock speed sensor ring by aligning the tab with the slot. - Start two bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes. 17. Press the new anti-lock speed sensor ring and the ring gear on the differential case. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6333 18. Install the bolts. - Apply Stud and Bearing Mount EOAZI9554-BA or equivalent meeting Ford specification WSK-M2G349-AI to the bolt threads. 19. Install the differential case. Removal and Installation Special Tools Special Tools Special Service Tool(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6334 Removal 1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and visually inspect the parts for wear and damage. 3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 4. Note: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Position the special tool and check the ring gear backlash and ring gear backface runout. 5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Loosen the differential case. 1. Remove the four bearing cap bolts. 2. Remove the two bearing caps. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6335 6. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. Use the pry bar and the wood block to remove the differential case from the rear axle housing. 7. Remove the 10 ring gear bolts. 8. CAUTION: Care should be taken not to damage the ring bolt hole threads. CAUTION: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6336 9. Install the differential case. - Position the differential case assembly, including the bearing cups and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts. 10. Position the special tool. 1. Rotate the differential case to make sure the differential bearings are correctly seated. 2. Position the special tool. 11. Note: If runout is less than the specification, install a new ring gear and pinion. If runout exceeds the specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and differential bearings. Measure the differential case runout without the ring gear. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6337 12. Remove the differential case from the rear axle housing and remove the differential bearings using the special tools. 13. Use the special tool to install the new differential bearings on the differential case. 14. Install the differential case. Position the differential case assembly, including the bearing cups and shims in the rear axle housing. Tighten bearing caps to specifications. 15. Measure the differential case runout without the ring gear, and check the case runout again with the new differential bearings. - If the runout is now less than the specification shown, use the new differential bearings for assembly. - If the runout is still excessive, the differential case is damaged and a new differential case must be installed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6338 Installation All vehicles 1. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case. - Align the notch on the differential case flange with the notch on the anti-lock speed sensor ring. 2. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-AI to ring gear bolts. 3. With pinion depth set and pinion installed, place the differential case in the rear axle housing. 4. Install a shim on the left side. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6339 5. CAUTION: Mark the position of the bearing caps as the arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Note: Apply pressure toward the left side to make sure the left bearing cap is seated. Install the left bearing cap and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential case to make sure it rotates freely. Measuring backlash Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6340 9. Use the special tool to measure the ring gear backlash. - If the backlash is within specification, go to Backlash within specification in this procedure. - If a zero backlash condition occurs, go to Zero backlash in this procedure. - If the backlash is not within specification, go to Backlash not within specification in this procedure. Zero backlash 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Cheek the backlash. Repeat Measuring backlash in this procedure. Backlash not within specification 11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown. - If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6341 12. Rotate the differential several times to make sure the differential bearings are correctly seated. 13. Using the special tool, recheck the backlash. - If the backlash is within specification, go to Backlash within specification in this procedure. If the backlash is not within specification, repeat measuring backlash in this procedure. Backlash within specification 14. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Using the special tool, make sure that the differential bearing shims are fully seated and the assembly turns freely. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6342 15. Install the bearing caps and bearing cap bolts. 16. Using the special tool, recheck the backlash. 17. Install the axle shafts. 18. Install the differential housing cover and refill the rear axle with specified lubricant. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > Customer Interest for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain Front Drive Axle Vent Tube Fluid Leaks Differential Cover: Customer Interest Drivetrain - Front Drive Axle Vent Tube Fluid Leaks TSB 05-6-20 04/04/05 FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 Explorer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac MERCURY: 1997-2001 Mountaineer This article supersedes TSB 03-05-08 to update the model year applications and to revise the Service Procedure. ISSUE Some Explorer/Mountaineer, Ranger and Explorer Sport/Sport Trac 4x4/AWD vehicles, may exhibit a fluid leak from the front axle vent tube. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Install a revised front axle cover kit. The revised cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE DO NOT FOLLOW THE SERVICE PROCEDURE OUTLINED IN THE DANA/SPICER INSTRUCTION SHEET INCLUDED IN THE COVER KIT. FOLLOW THE TSB SERVICE PROCEDURE. 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. Remove the lower engine splash shield, if equipped. 3. Index-mark the front axle pinion flange and the front driveshaft. 4. Remove the driveshaft bolts and retainers. Discard the driveshaft bolts. 5. Tape the U-joint bearing caps to prevent them from falling off the U-joint. 6. Swing the driveshaft away from the axle pinion yoke and secure out of the way. 7. Remove the three (3) axle support mounting bracket bolts from the axle housing. 8. Position suitable jack beneath axle housing. NOTE PLACE FOLDED SHOP TOWELS OR SUITABLE SOFT MATERIAL OVER TORSION BARS TO PROTECT THE HALFSHAFT BOOTS AND CLAMPS FROM DAMAGE. 9. Remove the two (2) bolts and nuts from the front axle support bushings. Discard the nuts. 10. Carefully lower and position the axle housing until it is resting on the torsion bars. 11. Disconnect the vent hose from the axle housing. 12. Position a drain pan under the axle housing cover. Rotate the axle housing slightly to allow easy access to the axle cover bolts. Remove the axle housing cover and discard. 13. Clean the axle housing cover mounting surface. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > Customer Interest for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain Front Drive Axle Vent Tube Fluid Leaks > Page 6351 14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing surface. 15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m). 16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the kit (Figure 1). 17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit. 18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque the bolts to 49 lb-ft (66 N.m). 19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106 N.m). 20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m). 21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90 Premium Rear Axle Lubricant. Install fill plug. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050620A 1995-2001 Explorer 1.5 Hrs. 1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac: Install A Revised Axle Cover Kit DEALER CODING CONDITION BASIC PART NO. CODE 4022 D1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > Customer Interest for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain Front Drive Axle Vent Tube Fluid Leaks > Page 6352 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks Differential Cover: All Technical Service Bulletins Drivetrain - Front Drive Axle Vent Tube Fluid Leaks TSB 05-6-20 04/04/05 FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 Explorer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac MERCURY: 1997-2001 Mountaineer This article supersedes TSB 03-05-08 to update the model year applications and to revise the Service Procedure. ISSUE Some Explorer/Mountaineer, Ranger and Explorer Sport/Sport Trac 4x4/AWD vehicles, may exhibit a fluid leak from the front axle vent tube. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Install a revised front axle cover kit. The revised cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE DO NOT FOLLOW THE SERVICE PROCEDURE OUTLINED IN THE DANA/SPICER INSTRUCTION SHEET INCLUDED IN THE COVER KIT. FOLLOW THE TSB SERVICE PROCEDURE. 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. Remove the lower engine splash shield, if equipped. 3. Index-mark the front axle pinion flange and the front driveshaft. 4. Remove the driveshaft bolts and retainers. Discard the driveshaft bolts. 5. Tape the U-joint bearing caps to prevent them from falling off the U-joint. 6. Swing the driveshaft away from the axle pinion yoke and secure out of the way. 7. Remove the three (3) axle support mounting bracket bolts from the axle housing. 8. Position suitable jack beneath axle housing. NOTE PLACE FOLDED SHOP TOWELS OR SUITABLE SOFT MATERIAL OVER TORSION BARS TO PROTECT THE HALFSHAFT BOOTS AND CLAMPS FROM DAMAGE. 9. Remove the two (2) bolts and nuts from the front axle support bushings. Discard the nuts. 10. Carefully lower and position the axle housing until it is resting on the torsion bars. 11. Disconnect the vent hose from the axle housing. 12. Position a drain pan under the axle housing cover. Rotate the axle housing slightly to allow easy access to the axle cover bolts. Remove the axle housing cover and discard. 13. Clean the axle housing cover mounting surface. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 6358 14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing surface. 15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m). 16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the kit (Figure 1). 17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit. 18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque the bolts to 49 lb-ft (66 N.m). 19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106 N.m). 20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m). 21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90 Premium Rear Axle Lubricant. Install fill plug. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050620A 1995-2001 Explorer 1.5 Hrs. 1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac: Install A Revised Axle Cover Kit DEALER CODING CONDITION BASIC PART NO. CODE 4022 D1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 6359 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Differential Cover: Specifications Front Differential housing cover bolt ............................................................................................................................................................ 22 Nm (16 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front > Page 6362 Differential Cover: Specifications Rear Torque Specifications Differential housing cover bolts ........................................................................................................................................................... 45 Nm (33 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 6363 Differential Cover: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the differential housing cover. 1. Loosen the bolts and drain the lubricant from the rear axle housing. 2. Remove the bolts. 3. Remove the differential housing cover. Installation 1. CAUTION: Make sure the machined surface on the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. To prevent contamination, cover the inside of the rear axle prior to cleaning the machined surface. Clean the rear axle housing and the differential housing cover gasket mating surfaces. 2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. Apply a new continuous bead of sealant to the differential housing cover. Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A. 3. Note: If possible, allow one hour before filling the axle with lubricant to make sure the silicone sealant has cured. Install the differential housing cover. 1. Install the differential housing cover. 2. Install the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 6364 4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml. (4 oz.) of Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. Note: In-vehicle repair refill capacities are determined by filling the rear axle to the level shown. Fill the rear axle. For vehicles with 4.0L SOHC and 4.0L EI with Traction-Lok rear axles and 5.0L, use 2.4 liters (5.5 pints) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-1 9580-B or equivalent meeting Ford specification WSL-M2C192-A, and install the filler plug - For vehicles with 4.0L SOHC and 4.0L EI with conventional rear axles, use 2.4 liters (5.5 pints) of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 5. Lower the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications Filler plug ............................................................................................................................................. .................................................... 30 Nm (22 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Axle ............................................................................................................................................ ..................................................................... 2.7 pints Rear Convetionial ........................................... .......................................................................................................................................................... 5.5 pints Rear Trac Lok ....................................................................................................................... ......................................................................................... 4 oz. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 6372 Fluid - Differential: Fluid Type Specifications Front Differential Fluid Type Motorcraft SAE 80W90 XL-80W90-QL Thermally Stable 4x4 Axle Lubricant Specification ................ .............................................................................................................................................................. ................. WSP-M2C197-A Rear Differential Fluid Type Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A for 4.0L SOHC and 4.0L EI with a conventional differential. Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A for 4.0L SOHC and 4.0L EI with a limited slip differential and 5.0L. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Pinion Bearing: Specifications Pinion bearing preload (new pinion bearings) 15 - 30 in.lb Pinion bearing preload (original pinion bearings) The reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken during disassembly Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front > Page 6377 Pinion Bearing: Specifications Pinion bearing preload (used pinion bearings) 8 - 14 in.lb Pinion bearing preload (new pinion bearings) 16 - 29 in.lb Differential bearing cap bol 77 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair Pinion Flange: Service and Repair Special Tools Removal 1. CAUTION: Do not allow the calipers to hang from the brake hoses. Note: Remove the rear wheels and the rear disc brake calipers to prevent brake drag during the drive pinion bearing preload adjustment. Remove the rear disc brake calipers. 2. Index-mark the driveshaft flange and pinion flange to maintain initial balance during installation. 3. Remove the four bolts and disconnect the d rive shaft. - Position the driveshaft aside. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 6381 4. Install a Nm (inch-pound) torque wrench on the pinion nut, and record the torque necessary to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation. Use the special tool to hold the pinion flange while removing the pinion nut. 6. Index-mark the pinion flange and the drive pinion stem to maintain initial balance during installation. 7. Using the special tool, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. - For vehicles with 4.0L SOHC and 4.0L EI with Traction-Lok(r) differentials and 5.0L, use Motorcraft Synthetic 75W140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For vehicles with 4.0L SOHC and 4.0L EI with conventional differentials, use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 6382 2. Note: Disregard the scribe marks if installing a new pinion flange. Align the pinion flange with the drive pinion shaft. 3. Using the special tools, install the pinion flange. 4. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut. CAUTION: Remove the special tool when taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the pinion nut. Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded. - Refer to the torque specification for used pinion bearings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 6383 5. CAUTION: Be sure to align the index-marks. Connect the driveshaft. 6. Install the rear disc brake calipers. 7. Install the rear wheel and tire assemblies. 8. Refer to the specified axle lubricant type and fill capacity. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair Pinion Gear: Service and Repair Special Tools Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6387 Special Tools Special Tools Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6388 Special Tools Removal 1. Remove the differential case. 2. CAUTION: Record the torque necessary to maintain rotation of the pinion through several revolutions prior to removing the pinion flange (48S1). Remove the pinion flange. 3. Remove the rear axle drive pinion seal. 4. Remove the rear axle drive pinion shaft oil slinger. 5. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer pinion bearing, and remove the pinion through the rear of the housing. 6. Remove the outer pinion bearing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6389 7. Remove and discard the collapsible spacer. 8. Using the special tool and a suitable press, remove the inner pinion bearing. 9. Note: Do not remove the pinion bearing cups from the axle housing unless the cups are damaged. To remove the bearing cups, tap alternately (with a brass drift of suitable length) on opposite sides of the cup to prevent the cup from cocking in the casting. Installation Using 205-024 1. Position the special tools and the inner and outer bearing cups in their respective axle housing bores. 1. After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup. 2. Place the special tool (outer) on the outer pinion bearing cup. 3. Install the special tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6390 2. Tighten the special tool to scat the pinion bearing cups in their bores. Using 205-153 and 205-DOS5 3. Using the special tools, drive the outer pinion bearing cup into the axle housing. 4. Using the special tools, drive the inner pinion bearing cup into the axle housing. Setting pinion depth 5. CAUTION: Always install new pinion bearings when installing new bearing cups. Note: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6391 6. Note: Apply only a light oil film on the pinion bearings before assembling the tools. Assemble and position the special tools and pinion bearings in the axle housing. 1. Position the Screw. 2. Position the Aligning Adapter. 3. Position the inner pinion bearing. 4. Position the Gauge Disc. 5. Position the Gauge Block. 6. Position the outer pinion bearing. 7. Thread on the Handle. 7. Note: This step simulates pinion bearing preload. Using a Nm (inch-pound) torque wrench, tighten the Handle to the specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6392 8. Note: Offset the Gauge Block to obtain an accurate reading. Rotate the Gauge Block several half-lures to make sure of correct seating of the pinion bearings and position the Gauge Block. 9. Install the special tool. 1. Position the special tool. 2. Install the bearing caps. 3. Install the four bolts. 10. Note: Use only flat, clean drive pinion bearing adjustment shims. Note: Selection of too thick a pinion shim results in a deep tooth contact at final assembly of integral rear axle assemblies. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. - After determining the correct shim thickness, remove the special tools. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6393 11. Using the special tool and a suitable press, seat the pinion bearing firmly against the pinion gear. 12. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. Install the outer pinion bearing. 14. Install the rear axle drive pinion shaft oil slinger. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6394 15. CAUTION: Installation without the correct tool can result in early seal failure. Note: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Place the rear axle drive pinion seal on the special tool. 16. CAUTION: If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Place the special tool and seal in the pinion seal bore and drive the rear axle drive pinion seal into place. 17. Install the pinion assembly (pinion, shims, inner pinion bearing, and collapsible spacer) into the rear axle housing bore. 18. Lubricate the pinion flange splines. - Vehicles with 4.0L SOHC and 4.0L EI with a conventional differential, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. - Vehicles with 4.0L SOHC and 4.0L EI with Limited Slip differential and 5.0L, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 19. Note: Disregard the alignment marks if installing a new pinion flange. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 6395 Align the pinion flange with the drive pinion shaft. 20. Using the special tools, install the pinion flange. 21. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut. CAUTION: Remove the special tool when taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. - If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to the torque specification for new pinion bearings. 22. Install differential case and the remaining components. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Ring Gear: Specifications Front General Specifications Ring gear backlash mm (inch) .................................................................................................................................................... 0.13-0.20 (0.005-0.008) Torque Specifications Ring gear bolt ...................................................................................................................................... .............................................. 109 Nm (80 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front > Page 6400 Ring Gear: Specifications Rear Clearance, Tolerance and Adjustments Maximum ring gear backface runout ............................................................................................................................................ 0.102 mm (0.004 inch) Backlash between ring gear and pinion teeth .............................................................................................................................................................. .................................. 0.203 mm (0.008 inch) ...................................................................................... .......................................................................................................... 0.381 mm (0.015 inch) .............. .............................................................................................................................................................. .................... 0.305 mm (0.012 inch) .................................................................................................... ............................................................................ 0.381 mm (0.015 inch) preferred Maximum ring gear backlash variation between teeth .................................................................................................................. 0.102 mm (0.004 inch) Torque Specifications Ring gear bolts .................................................................................................................................... .................................... 95-115 Nm (70-85 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Seals and Gaskets: Service and Repair Front Special Tools Special Tools Removal CAUTION: This operation disturbs the differential pinion bearing preload. Carefully reset the preload during assembly. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle 2. Index-mark the front driveshaft and pinion flange. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front > Page 6405 3. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect the front driveshaft from the pinion flange, and position it aside. 1. Remove the bolts and the universal joint spider retainers. 2. Disconnect the front driveshaft from the pinion flange. 3. Position the front driveshaft aside. 4. Measure the pinion bearing preload. - Using a Nm (inch-pound) torque wrench, measure the torque required to maintain pinion rotation. Record the measurement. 5. Index-mark the pinion flange and the pinion stem. 6. Use the special tool to hold the pinion flange while removing the nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front > Page 6406 7. CAUTION: Place a drain pan under the differential housing. Using the special tool, remove the pinion flange. 8. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange as necessary. 9. Using the special tool and a suitable impact slide hammer, remove the pinion seal. 10. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing. 11. Remove and discard the collapsible spacer. Installation 1. Verify that the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth. Work in a rotating motion to wipe the pinion clean. 2. Clean the pinion seal bore. 3. Install a new collapsible spacer. 4. Install the original differential pinion bearing and the front axle drive pinion shaft oil slinger. 5. Lubricate the pinion seal. - Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front > Page 6407 6. Using the special tool, install the pinion seal. 7. Lubricate the pinion flange splines. - Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. 8. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting Range. Align the index marks and install the pinion flange. 9. Install the new nut hand-tight. 10. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary. Use the special tool to hold the pinion flange while tightening the nut to set the preload. Tighten the nut, rotating the pinion occasionally to ensure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken during removal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front > Page 6408 11. Align the index marks and position the front driveshaft. 12. Install the universal joint spider retainers and bolts. 13. Check the fluid level and, if necessary, fill the axle to specification. - Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. 14. Lower the vehicle. 15. If so equipped, reactivate the air suspension. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front > Page 6409 Seals and Gaskets: Service and Repair Rear Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer until the rear axle drive pinion seal is removed. Installation 1. Lubricate the new rear drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1 C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Specifications Driveshaft to Driveshaft Rear Axle Pinion Flange Bolts 83 ft.lb Front Driveshaft to Front Axle Bolts 11 - 15 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type > Page 6416 Axle Shaft: Specifications Maximum axle shaft end play 0.03 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6417 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6418 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6419 Axle Shaft: Description and Operation Front Drive Halfshafts Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6420 Front Drive Halfshaft and Joint Assembly The front wheel driveshaft joints: transmit equal engine torque from the axle to both front wheels. - use a constant velocity (CV) joint, at both the inboard and outboard ends, for operating smoothness. - rotate at approximately one-third the speed of a driveshaft and do not normally contribute to any rotational vibration that may occur. The only replaceable components of the front wheel driveshaft and joints are: Wheel driveshaft and joint boots (inboard and outboard). The replacement kit includes wheel driveshaft and joint boots and clamps, snap rings, retainer ring and grease. - Inboard CV joint (plunge type). - Side shaft. Replacement includes the outboard front wheel halfshaft joint (fixed type), outboard boot and clamps, front wheel excluder seal (assembled on the interconnecting shaft). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Axle Shaft: Symptom Related Diagnostic Procedures 1 of 2 2 of 2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6423 Axle Shaft: Component Tests and General Diagnostics Note: Constant velocity (CV) joints must not be replaced unless disassembly and inspection reveals unusual wear. Note: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. - Inspect the boots for evidence of cracks, tears, or splits. - Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type Bushing Special Service Tool(s) Removal 1. Note: Axle tube bushing removal shown, axle housing bushing is a similar procedure. Remove the front axle assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6426 2. Position the tube bushing removal tools. 1. Position the Bushing Cup Remover/Replacer. 2. Position the Drawbolt. 3. Thread the Bushing Remover on the Drawbolt. 3. Tighten the Drawbolt to remove the tube bushing. Installation 1. Note: Axle tube bushing installation shown, axle housing bushing is a similar procedure. Position the tube bushing and the tube bushing installation tools. 1. Position the tube bushing. 2. Position the Ring Gauge. 3. Position the Bushing Collet Replacer. 4. Position the Bushing Cup Remover/Replacer. 5. Position the Drawbolt. 6. Thread the Bushing Replacer on the Drawbolt. 2. Tighten the Drawbolt to install the tube bushing. - Remove the tools. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6427 3. Install the front axle assembly. 4. Check the fluid level and fill the axle to specification. - Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. 5. Lower the vehicle. 6. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Disassembly and Assembly Special Tools Disassembly 1. Remove the front wheel halfshaft. 2. CAUTION: Be careful not to damage the halfshaft boot. Remove the two inboard boot clamps. 3. Slide the inboard halfshaft boot off the inboard CV joint housing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6428 4. Separate the CV joint from the CV joint housing. 5. Mark the shaft and the inboard CV joint to ease alignment during assembly. 6. Remove the snap ring. 7. Remove the CV joint. 8. Remove the inboard halfshaft boot from the shaft assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6429 9. Remove the two outboard boot clamps. 10. Remove the outboard halfshaft boot. 11. Note: If grease is contaminated, clean and inspect the joint for wear. Replace the outboard CV joint and shaft assembly if worn or damaged. Inspect for contaminated grease. Assembly 1. Pack the outboard CV joint with grease. 1. Use Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A. 2. Spread any remaining grease from the service kit evenly inside the outboard halfshaft boot. 2. Note: Clean the halfshaft boot mounting surfaces of access grease before positioning the halfshaft boot into place. Position the outboard halfshaft boot and outboard boot clamps. 1. Position the outboard halfshaft boot. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6430 2. Position the boot clamps on the outboard halfshaft boot. 3. Note: Tighten the through-bolt until the installer is in the closed position. Use the CV Boot Clamp Installer to install the outboard CV joint boot clamps. 4. Position the boot clamp on the halfshaft. 5. Position the inboard halfshaft boot. 6. Install the CV joint on the halfshaft. 1. Line up the marks on the halfshaft and the CV joint. 2. Install the CV joint on the halfshaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6431 7. Install the snap ring. 8. Lubricate the three CV joint needle bearings. - Use Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A. 9. Fill the inboard CV joint housing with 235 grams of grease. - Use Ford High Temp Constant Velocity Joint Grease E43Z-1 9590-A or equivalent meeting Ford specification ESP-M1C207-A. 10. Position the CV joint housing onto the CV joint. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6432 11. Note: Remove any excess grease from the inboard halfshaft boot mating surface before positioning into place. Position the inboard halfshaft boot and boot clamp. 1. Position the inboard halfshaft boot into place. 2. Position the boot clamp. 12. Insert a dulled screwdriver blade to relieve built-up air pressure in the halfshaft boot. 13. Use the CV Boot Clamp Installer to install the inboard boot clamps. 14. Install the front wheel halfshaft. Removal and Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6433 Special Tools Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. CAUTION: Discard the wheel hub retainer nut and washer assembly. It is a torque prevailing design and cannot be reused. Remove the wheel hub retainer nut and washer assembly. 4. Position the disc brake caliper aside. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6434 1. Remove the two front disc brake caliper bolts. 2. Lift the front disc brake caliper off the front disc brake caliper anchor plate and position aside. 5. Remove the brake discs. 6. CAUTION: Do not use a hammer to separate the outboard front wheel halfshaft joint from the hub. Damage to the outboard CV joint stub shaft housing threads and internal components may result. Install the special tool and separate the halfshaft from the hub. Remove the special tool. 7. Support the front suspension lower arm. 8. Remove the upper ball joint to front wheel knuckle nut and bolt. 9. Remove the outboard front wheel driveshaft and joint from the hub. 1. Rotate the front wheel knuckle. 2. Compress the outboard front wheel driveshaft and joint. 3. Remove the outboard front wheel driveshaft and joint from the wheel hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6435 10. Using the CV Joint Puller and Impact Slide Hammer, separate the front wheel driveshaft and joint from the front axle housing. 11. Remove the front wheel driveshaft and joint from the front axle housing. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6436 1. CAUTION: A new front axle wheel hub retaining nut and washer assembly must be installed. CAUTION: Do not use power or impact tools to tighten the hub nut and washer assembly. CAUTION: Do not reuse the retainer circlip. A new circlip must be installed each time the inboard CV joint stub shaft housing is installed into the differential. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6437 Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover. 1. Loosen the bolts and drain the lubricant from the rear axle housing. 2. Remove the bolts. 3. Remove the differential housing cover. 4. Remove the rear brake disc. 5. CAUTION: Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components. Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Remove the U-washer. 1. Push the axle shaft inboard. 2. Remove the U-washer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6438 7. Reinstall the differential pinion shaft. 1. Install the differential pinion shaft. 2. Install the differential pinion shaft lock bolt finger-tight. 8. CAUTION: Do not damage the wheel bearing oil seal. Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components. Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6439 3. CAUTION: Do not damage the wheel bearing oil seal. Install the axle shaft. 4. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Install the U-washer. 1. Position the U-washer on the button end of the axle shaft. 2. Pull the axle shaft outward. 5. CAUTION: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. Install the differential pinion shaft. 1. Align the hole in the differential pinion shaft with the differential pinion shaft lock bolt hole. 2. Install a new differential pinion shaft lock bolt. 6. Install the rear brake disc. 7. Install the differential housing cover, and fill the rear axle housing with the specified lubricant type and quantity. 8. Install the wheel and tire assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-11-4 > Jun > 01 > Front Axle - Squealing/Whistling Noise Seals and Gaskets: Customer Interest Front Axle - Squealing/Whistling Noise Article No. 01-11-4 06/11/01 ^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS ^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: 1998-2001 MOUNTAINEER This article is being republished in its entirety to update the model applications covered. This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001 Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built after 11/1/1999 only. ISSUE Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may be more pronounced in cold weather conditions. ACTION Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL NUMBERS ARE D93P-1175-A AND D93P-1175-B. Perform the following for each side of the vehicle: 1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year Workshop Manual. 2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise on the exposed metal surface only. The CV joint should be in an upright position (splined end up). Be careful not to damage the boot or boot clamp. 3. Remove the old seal by prying it off the shaft. 4. Clean the outer race of the CV joint of any remaining foreign matter. 5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing the bell of the joint (away from the stem). NOTE BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-11-4 > Jun > 01 > Front Axle - Squealing/Whistling Noise > Page 6448 UNTIL IT IS FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO AVOID DAMAGING THE RUBBER PORTION OF THE SEAL. 6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease (E8TZ-19590-A) onto the new seal lips. 7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will ride against. 8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop Manual. 9. Verity that the noise is no longer present. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible Under The Provision Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-11-4 > Jun > 01 > Front Axle - Squealing/Whistling Noise Seals and Gaskets: All Technical Service Bulletins Front Axle - Squealing/Whistling Noise Article No. 01-11-4 06/11/01 ^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS ^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: 1998-2001 MOUNTAINEER This article is being republished in its entirety to update the model applications covered. This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001 Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built after 11/1/1999 only. ISSUE Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may be more pronounced in cold weather conditions. ACTION Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL NUMBERS ARE D93P-1175-A AND D93P-1175-B. Perform the following for each side of the vehicle: 1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year Workshop Manual. 2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise on the exposed metal surface only. The CV joint should be in an upright position (splined end up). Be careful not to damage the boot or boot clamp. 3. Remove the old seal by prying it off the shaft. 4. Clean the outer race of the CV joint of any remaining foreign matter. 5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing the bell of the joint (away from the stem). NOTE BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-11-4 > Jun > 01 > Front Axle - Squealing/Whistling Noise > Page 6454 UNTIL IT IS FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO AVOID DAMAGING THE RUBBER PORTION OF THE SEAL. 6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease (E8TZ-19590-A) onto the new seal lips. 7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will ride against. 8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop Manual. 9. Verity that the noise is no longer present. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible Under The Provision Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6455 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-11-4 Date: 010611 Front Axle - Squealing/Whistling Noise Article No. 01-11-4 06/11/01 ^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS ^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: 1998-2001 MOUNTAINEER This article is being republished in its entirety to update the model applications covered. This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001 Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built after 11/1/1999 only. ISSUE Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may be more pronounced in cold weather conditions. ACTION Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL NUMBERS ARE D93P-1175-A AND D93P-1175-B. Perform the following for each side of the vehicle: 1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year Workshop Manual. 2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise on the exposed metal surface only. The CV joint should be in an upright position (splined end up). Be careful not to damage the boot or boot clamp. 3. Remove the old seal by prying it off the shaft. 4. Clean the outer race of the CV joint of any remaining foreign matter. 5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing the bell of the joint (away from the stem). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6456 NOTE BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL UNTIL IT IS FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO AVOID DAMAGING THE RUBBER PORTION OF THE SEAL. 6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease (E8TZ-19590-A) onto the new seal lips. 7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will ride against. 8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop Manual. 9. Verity that the noise is no longer present. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible Under The Provision Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300 Technical Service Bulletin # 01-11-4 Date: 010611 Front Axle - Squealing/Whistling Noise Article No. 01-11-4 06/11/01 ^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS ^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER HALFSHAFT DUST SEALS FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6457 1998-2001 MOUNTAINEER This article is being republished in its entirety to update the model applications covered. This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001 Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built after 11/1/1999 only. ISSUE Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may be more pronounced in cold weather conditions. ACTION Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL NUMBERS ARE D93P-1175-A AND D93P-1175-B. Perform the following for each side of the vehicle: 1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year Workshop Manual. 2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise on the exposed metal surface only. The CV joint should be in an upright position (splined end up). Be careful not to damage the boot or boot clamp. 3. Remove the old seal by prying it off the shaft. 4. Clean the outer race of the CV joint of any remaining foreign matter. 5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing the bell of the joint (away from the stem). NOTE BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL UNTIL IT IS FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO AVOID DAMAGING THE RUBBER PORTION OF THE SEAL. 6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease (E8TZ-19590-A) onto the new seal lips. 7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will ride against. 8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop Manual. 9. Verity that the noise is no longer present. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible Under The Provision Of Bumper To Bumper Warranty Coverage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6458 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Page 6459 Seals and Gaskets: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Page 6460 Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6466 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6467 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Special Service Tool(s) Removal 1. Remove the brake disc. 2. Remove the three bolts and the dust shield. 3. CAUTION: Discard the wheel hub retainer nut and washer assembly. It is a torque prevailing design and cannot be reused. Remove the wheel hub retainer nut and washer assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6470 4. Remove the front brake anti-lock sensor. 1 Remove the bolt. 2 Remove the front brake anti-lock sensor. 5. CAUTION: Do not overextend CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the three bolts and the wheel hub. 6. Remove the seal. Installation 1. Install the seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6471 ^ Using the Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer, install the seal. 2. Install the wheel hub. ^ Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. Install the three bolts. 3. Install the dust shield. 4. Install the front brake anti-lock sensor. 1 Position the front brake anti-lock sensor. 2 Install the bolt. 5. Install the wheel hub retainer nut and washer assembly. 6. Install the brake disc. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6472 Wheel Bearing: Service and Repair Rear Special Tools Special Tools Removal 1. Remove the axle shaft. See: Axle Shaft Assembly/Axle Shaft/Service and Repair 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6473 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Hub Nut 157-213 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 00-8-3 > Apr > 00 > Exhaust/Driveshaft - Rubbing Noise On R/H Turns Drive/Propeller Shaft: Customer Interest Exhaust/Driveshaft - Rubbing Noise On R/H Turns Article No. 00-8-3 DATE: 04/17/2000 NOISE - "RUBBING" FROM REAR OF VEHICLE DURING RIGHT HAND TURNS - VEHICLES EQUIPPED WITH 5.0 L ENGINE BUILT THROUGH 1/5/2000 FORD: 1996-2000 EXPLORER MERCURY: 1996-2000 MOUNTAINEER ISSUE Some vehicles equipped with 5.OL engine may exhibit a rubbing noise during right hand turns from the rear of the vehicle. This may be due to insufficient clearance between the muffler hanger rod and the rear driveshaft This condition generally occurs when the muffler inlet pipe slip joint does not completely slide over the converter outlet pipe and causes the muffler assembly to pull inboard during assembly. ACTION Replace the muffler assembly and hanger bracket. The revised muffler assembly (YL2Z-5230-AA) has hanger rods that have been re-oriented 90 degrees which when used with the new hanger bracket (F57Z-5A246-A) allows the system to swing fore-aft (same as the 4.OL OHV system) and prevents the potential contact with the rear driveshaft. Refer to section 309-00 of the appropriate model year Workshop Manual for standard exhaust system repair procedures. NOTE: When the new muffler assembly (YL2Z-5230-AA) is installed, the new hanger bracket (F57Z-5A246-A) must also be used. PART NUMBER PART NAME YL2Z-5230-AA Muffler Assembly F57Z-5A246-A Hanger Bracket OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 597997, 702000, 702200,702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 00-8-3 > Apr > 00 > Exhaust/Driveshaft - Rubbing Noise On R/H Turns Drive/Propeller Shaft: All Technical Service Bulletins Exhaust/Driveshaft - Rubbing Noise On R/H Turns Article No. 00-8-3 DATE: 04/17/2000 NOISE - "RUBBING" FROM REAR OF VEHICLE DURING RIGHT HAND TURNS - VEHICLES EQUIPPED WITH 5.0 L ENGINE BUILT THROUGH 1/5/2000 FORD: 1996-2000 EXPLORER MERCURY: 1996-2000 MOUNTAINEER ISSUE Some vehicles equipped with 5.OL engine may exhibit a rubbing noise during right hand turns from the rear of the vehicle. This may be due to insufficient clearance between the muffler hanger rod and the rear driveshaft This condition generally occurs when the muffler inlet pipe slip joint does not completely slide over the converter outlet pipe and causes the muffler assembly to pull inboard during assembly. ACTION Replace the muffler assembly and hanger bracket. The revised muffler assembly (YL2Z-5230-AA) has hanger rods that have been re-oriented 90 degrees which when used with the new hanger bracket (F57Z-5A246-A) allows the system to swing fore-aft (same as the 4.OL OHV system) and prevents the potential contact with the rear driveshaft. Refer to section 309-00 of the appropriate model year Workshop Manual for standard exhaust system repair procedures. NOTE: When the new muffler assembly (YL2Z-5230-AA) is installed, the new hanger bracket (F57Z-5A246-A) must also be used. PART NUMBER PART NAME YL2Z-5230-AA Muffler Assembly F57Z-5A246-A Hanger Bracket OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 597997, 702000, 702200,702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6492 Drive/Propeller Shaft: Specifications Rear Driveshaft Bolts 65-87 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Driveshaft Drive/Propeller Shaft: Diagrams Driveshaft Driveshaft-Rear, 4X2 1 of 3 2 of 3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Driveshaft > Page 6495 3 of 3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Driveshaft > Page 6496 Drive/Propeller Shaft: Diagrams Universal Joints 1 of 2 2 of 2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints Drive/Propeller Shaft: Description and Operation Universal Joints The universal joints are: lubed-for-life design and require no lubrication. - equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearing and improve grease movement. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints > Page 6499 Drive/Propeller Shaft: Description and Operation Driveshaft Note: Whenever the vehicle is raised on a hoist, inspect the universal joint slip yoke boot for rips or holes. Replace if required. Note: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and universal joints to prevent application of any undercoating material. Note: The constant velocity (CV) joint on the front driveshaft is not serviceable. The front driveshaft is connected to the transfer case and the front drive axle by a driveshaft flange yoke. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front Drive/Propeller Shaft: Service and Repair Driveshaft-Front Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the front axle pinion flange to the front driveshaft. 3. Remove the transfer case skid plate. 4. Index-mark the transfer case pinion flange to the front driveshaft. 5. Remove the front driveshaft CV joint-to-transfer case bolts and washers. 6. Remove the front driveshaft-to-front axle bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6502 7. Note: Always disconnect the front driveshaft from the transfer case first. Remove the front driveshaft. Installation 1. Note: Install new front driveshaft CV joint-to-transfer case bolts and washers and new front driveshaft-to-front axle bolts and straps. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. Note: Always install the front driveshaft at the front axle first. To install, follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6503 Drive/Propeller Shaft: Service and Repair Driveshaft-Rear, 4X2 Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the driveshaft to driveshaft rear axle pinion flange. 3. Note: Index-mark the driveshaft slip yoke to the transmission output shaft. Remove the driveshaft. 1. Remove and discard the four bolts, and disconnect the driveshaft. 2. Lower the driveshaft, and slide the driveshaft rearward out of the transmission. - Plug the extension housing to prevent fluid loss. Installation 1. Note: Install new rear driveshaft-to-driveshaft rear axle pinion flange bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. To install, follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6504 Drive/Propeller Shaft: Service and Repair Driveshaft-Rear, 4X4 Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the driveshaft yoke to the transfer case pinion flange. 3. Index-mark the driveshaft to driveshaft rear axle pinion flange. 4. Remove the four rear bolts, and disconnect the rear driveshaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6505 5. Separate the driveshaft from the transfer case. 1. Remove the four bolts. 2. Carefully remove the driveshaft. Installation 1. Note: Install new rear driveshaft-to-driveshaft rear axle pinion flange bolts and driveshaft flange yoke-to-transfer case bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. To install, follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair Slip Yoke: Service and Repair Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Remove the driveshaft slip yoke boot. 1. Index-mark the driveshaft to the driveshaft slip yoke. 2. With the rear driveshaft on a bench, cut and discard the driveshaft slip yoke boot clamps. 3. Separate the driveshaft slip yoke from the splined stub shaft on the driveshaft, and remove the driveshaft slip yoke boot. - Inspect the driveshaft slip yoke boot for damage and replace if required. 3. Inspect the lubricant for contamination. If contaminated, inspect the stub shaft and driveshaft slip yoke for wear. Replace the driveshaft as needed. Assembly 1. Slide the small opening end of the driveshaft slip yoke boot on the splined stub shaft as far as it will travel. 2. Install the small driveshaft slip yoke boot clamp and use Keystone Clamp Pliers to crimp the small driveshaft slip yoke boot clamp. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair > Page 6509 3. Install the driveshaft slip yoke. 1. Lubricate the stub shaft splines, and pull the driveshaft slip yoke boot towards the driveshaft. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 2. Fill the driveshaft slip yoke boot with approximately 10 grams of lubricant. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 3. Position the large driveshaft slip yoke boot clamp. 4. Align the index marks made during disassembly, and install the driveshaft slip yoke. 4. Install the large driveshaft slip yoke boot clamp. 1. Remove any excess grease from the differential slip yoke boot and driveshaft slip yoke surfaces. 2. Position the driveshaft slip yoke boot over the driveshaft slip yoke boot groove. 3. Position the driveshaft slip yoke to specification from the driveshaft weld to the end of the slip yoke splines. 4. Bleed air from the driveshaft slip yoke boot. 5. Use Keystone Clamp Pliers to crimp the large driveshaft slip yoke boot clamp. 5. Install the driveshaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Specifications Universal Joint: Specifications Universal joint spider retainer bolt 14 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke Universal Joint: Service and Repair Single Cardan, Flange Yoke Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. Note: If components are not marked and installed correctly, driveline imbalance can occur. Index-mark the positions of the driveshaft components. 4. Clamp the U joint tool in a vise. 5. Remove all four of the snap rings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6515 6. Remove the driveshaft flange yoke. 1. Position the driveshaft flange yoke in the U-joint tool. 2. Press out a bearing cup. 3. Remove the driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft flange yoke. 7. Remove the spider. 1. Reposition the driveshaft in the U-joint tool. 2. Press out the bearing cup. 3. Rotate the driveshaft. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the spider. 8. Clean the yoke area at the end of the driveshaft. Assembly 1. Note: Universal joint kits are to be installed as complete assemblies only. Do not mix components from other U-joint kits. Install the spider. 1. Start a new bearing cup into the driveshaft yoke. - Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Position the driveshaft in the U joint tool. 4. Press the bearing cup to just below the snap ring groove. - Repeat for the other bearing cup. 2. Inspect the driveshaft flange yoke. Install new if necessary. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6516 3. Install the driveshaft flange yoke. 1. Start a new bearing cup into the driveshaft flange yoke. - Check the needle bearings for correct positioning. 2. Position the driveshaft flange yoke. 3. Position the driveshaft in the U-joint tool. 4. Press the bearing cup to just below the snap ring groove. - Repeat for the other bearing cup. 4. Note: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-joint tool, and install the four snap rings. 5. Note: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 6. Install the driveshaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6517 Universal Joint: Service and Repair Universal Joint -Single Cardan Special Tools Disassembly 1. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Be careful not to damage the tube. 2. Note: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. Index-mark the driveshaft components. 3. Clamp U-joint tool in a vise. 4. Remove all four of the snap rings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6518 5. Note: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft slip-yoke. 1. Position the driveshaft slip-yoke in the U-joint tool. 2. Press out a bearing cup. 3. Rotate the driveshaft slip-yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft slip-yoke. 6. Repeat Step 5 to remove the remaining bearing cups and spider from the driveshaft. 7. Clean the yoke area at each end of the driveshaft. Assembly 1. Note: Universal Joint Service Kits are to be installed as complete assemblies only. Do not mix components from other U-Joint Kits. Install the bearing cup. 1. Start a new bearing cup into the driveshaft yoke. Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Using the U-joint tool, press the bearing cup to just below the snap ring groove. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6519 2. Note: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U joint tool, and install the snap ring. 3. Repeat Steps 1 and 2 to install the opposite side of the driveshaft yoke. 4. Inspect the driveshaft slip-yoke. Install a new yoke, if necessary. 5. Repeat Steps 1 and 2 to install the remaining new bearing cups, spider, driveshaft slip-yoke, and the snap rings. 6. Note: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 7. Install the driveshaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel bolts 75 - 85 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6523 Flex Plate: Service and Repair Removal 1. Remove the transmission. 2. Remove the bolts and remove the flywheel. 3. Clean and inspect the flywheel. Installation 1. Note: Sealant must be removed from the bolt holes prior to reassembly. Note: If reusing the bolts, clean sealant from the bolts and apply Pipe Sealant with Teflon (R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A. Do not apply sealant to the new bolts. They come with sealant on them. Position the flywheel and install the bolts. 2. Install the transmission. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel Bolts 75 - 85 ft.lb Flywheel Runout 0.005 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel Flywheel: Service and Repair Dowels - Flywheel Removal 1. Note: Take care not to damage the flywheel dowel holes or surface areas around the flywheel dowel during removal. Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open hole, and locking pliers where the flywheel dowel is installed in a blind hole. Installation 1. Note: Care should be taken to drive the flywheel dowel squarely into place until fully seated and to not damage surrounding surface areas. Install all flywheel dowels by driving them into place using a brass or plastic mallet. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel > Page 6529 Flywheel: Service and Repair Flywheel - Removal and Installation Special Tools Removal 1. Remove the clutch disc and pressure plate. 2. CAUTION: Two bolts should be loosened but left in to prevent the flywheel from falling. Remove six of eight bolts. Loosen the two remaining bolts but leave in place. 3. Press the flywheel off the crankshaft. - Install the two bolts in the threaded holes in the flywheel and remove flywheel. 4. Remove the bolts remaining in the crankshaft. 5. Remove the flywheel. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel > Page 6530 1. Position the flywheel onto the crankshaft and install the flywheel-to-crankshaft bolts. - Apply Threadlock and Sealer EOAZ-1955AA or equivalent meeting Ford specification WSK-M2G315-A5 (Type II) to bolt threads. 2. Install the disc and pressure plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 6536 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 6540 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair Bell Housing: Service and Repair Removal 1. Note: Take care not to damage the flywheel housing-to-block dowel holes or surface areas around the flywheel housing-to-block dowel hole during removal. Remove the flywheel housing-to-block dowels using a drift pin where the flywheel housing-to-block dowel is installed in an open hole, and locking pliers where the flywheel housing-to-block dowel is installed in a blind hole. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Case Cover Bolts 12 - 16 ft.lb Case Plug 30 - 43 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Specifications Countershaft: Specifications Countershaft Locknut 94 - 144 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Drain Plug 30 - 43 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications Extension Housing: Specifications Torque Specifications Extension Housing Bolts ........................................................................................................................................................... 32-46 Nm (24-33 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6561 Extension Housing: Service and Repair Special Tools Removal 1. If equipped, turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. On 4WD vehicles, remove the transfer case. 5. Drain the transmission fluid. 6. Note: To maintain initial driveshaft balance, mark the driveshaft centering socket yoke and rear axle universal joint flange so they may be installed in their original positions. Mark the driveshaft centering socket yoke and rear axle universal joint flange. 7. Remove and support the rear driveshaft. 1. Remove the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6562 2. Remove the rear driveshaft. 8. Use the (A) Hi-Lift Jack to support the (B) transmission. - Secure the (B) transmission with the (C) strap. 9. Remove the nuts. 10. Remove the crossmember. 1. Remove the six bolts (three each side). 2. Remove the crossmember. 11. Remove the (RH) transmission mount bolt. 1. Remove the bolt. 2. Reposition the exhaust mounting bracket. 12. Lower the transmission to access extension housing bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6563 13. Use the Seal Remover to remove the extension housing seal. 14. Remove the extension housing. 1. Remove the bolts. 2. Remove the extension housing. Installation 1. Note: The extension housing must be installed within four minutes after applying silicone. Apply a small bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the surface of the case. 2. Install the extension housing. 1. Position the extension housing. 2. Install the bolts. 3. Use Extension Housing Seal Replacer to install the extension housing seal. 4. Raise and position the transmission. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6564 5. Install the (RH) transmission mount bolt. 1. Position the exhaust bracket. 2. Install the bolt. 6. install the crossmember. 1. Position the crossmember. 2. Install the six bolts and nuts (three each side). 7. Remove the Hi-Lift Jack. 8. Install the nuts. 9. Note: To maintain initial driveshaft balance, align marks on the rear driveshaft centering socket yoke and rear axle universal joint flange made during removal. Install the rear driveshaft. 1. Position the rear driveshaft. 2. Install the four bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6565 10. Fill the (A) transmission with MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent meeting Ford MERCON specification until it reaches the bottom of the (B) fill port and install the (C) case plug. 11. Lower the vehicle. 12. Connect the battery ground cable. 13. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications Fill Plug 30 - 43 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6573 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6574 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 6577 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF CAUTION: Using a transmission fluid that indicates a dual usage MERCON and MERCON V in a transmission application requiring MERCON, may cause internal transmission damage. The use of any fluid other than the recommended fluid may cause transmission damage. Some fluid labels may indicate dual usage such as MERCON and MERCON V. These dual-usage fluids are not to be used in transmissions that use only the MERCON type fluid. These dual-usage fluids may be used in transmissions that require MERCON V use. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T > Component Information > Service and Repair Flywheel Gear: Service and Repair Removal WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. Remove the flywheel. 2. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over heating. CAUTION: Tap the flywheel ring gear evenly to prevent binding. Remove the flywheel ring gear from the flywheel. Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear off the flywheel. Installation WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over heating. CAUTION: Keep the torch moving to prevent hot spots. Evenly heat the flywheel ring gear. 2. Install the flywheel ring gear. - The bevel on the flywheel ring gear must face the rear of the flywheel. - Use a brass drift. 3. Install the flywheel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Hub: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise Synchronizer Hub: Customer Interest M/T - M5OD Buzzing/Grinding Noise Article No. 00-3-6 02/07/00 ^ NOISE - "BUZZING" AND/OR "GRINDING" DURING 2-3 SHIFT - VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 ^ TRANSMISSION - M5OD - "BUZZING" AND/OR "GRINDING" NOISE DURING 2-3 SHIFT VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 FORD: 1998-2000 EXPLORER, RANGER ISSUE Some vehicles may exhibit a "buzzing" and/or "grinding" noise or a "notchy" feeling during the 2-3 upshift. This may be caused by the 3-4 synchronizer. ACTION Replace the 3-4 synchronizer assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE First, verify that vehicle exhibits a buzzing/grinding/notchy feeling/sensation during 2-3 upshift and determine it your transmission serial number is greater than the serial number listed below. If the vehicle does NOT exhibit a buzzing/grinding/notchy feeling/sensation and is greater than the serial number listed on the chart below, proceed with other appropriate diagnostics for repair. Reference the appropriate Workshop Manual for assistance. NOTE ALL TRANSMISSIONS WITH SERIAL NUMBERS GREATER THAN THE ONES LISTED BELOW ARE NOT AFFECTED. USE THE CHART BELOW AND THE SAMPLE TAG INFORMATION TO ASSIST IN DETERMINING IF THIS FIX IS APPLICABLE. THE TRANSMISSION SERIAL NUMBER IS LOCATED ON THE TAG ATTACHED TO THE LEFT SIDE OF THE TRANSMISSION. TRANSMISSION SERIAL NUMBER INFORMATION Transmission Application Tag Transmission Serial Number 2.5L I-4 4X2 F87A - AB less than 0629756 3.0L V-6 4X2 F87A - CA less than 0628220 3.0L V-6 4X4 F87A - DA less than D624514 4.0L V-6 4X2 F87A - EA less than D639401 4.0L V-6 4X4 FB7A - FA less than 0627480 1. Drain all fluid from the transmission and remove the transmission following the procedure outlined in the appropriate Workshop Manual. 2. Disassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 3. Inspect the brass blocking rings for any damage. If they are not damaged, reuse on reassembly. 4. Replace the synchronizer. Additionally, replace brass blocking rings if necessary. 5. Reassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 6. Reinstall the transmission and fill with new fluid. Test drive to verify repair. NOTE AFTER THE REPAIR, THE TRANSMISSION MAY FEEL STIFF, ESPECIALLY IF THE BRASS BLOCKING RINGS WERE REPLACED. THIS WILL GO AWAY AFTER DRIVING THE VEHICLE FOR SEVERAL KILOMETERS/MILES, AS THE NEW BLOCKING RINGS NEED TIME TO RESEAT AGAINST THE GEAR CONE. PART NUMBER PART NAME F2TZ-7124-AB Synchronizer Assembly (2.5L And 3.0L) F2TZ-7124-CA Synchronizer Assembly (4.0L) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Hub: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise > Page 6590 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 505000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Hub: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise Synchronizer Hub: All Technical Service Bulletins M/T - M5OD Buzzing/Grinding Noise Article No. 00-3-6 02/07/00 ^ NOISE - "BUZZING" AND/OR "GRINDING" DURING 2-3 SHIFT - VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 ^ TRANSMISSION - M5OD - "BUZZING" AND/OR "GRINDING" NOISE DURING 2-3 SHIFT VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 FORD: 1998-2000 EXPLORER, RANGER ISSUE Some vehicles may exhibit a "buzzing" and/or "grinding" noise or a "notchy" feeling during the 2-3 upshift. This may be caused by the 3-4 synchronizer. ACTION Replace the 3-4 synchronizer assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE First, verify that vehicle exhibits a buzzing/grinding/notchy feeling/sensation during 2-3 upshift and determine it your transmission serial number is greater than the serial number listed below. If the vehicle does NOT exhibit a buzzing/grinding/notchy feeling/sensation and is greater than the serial number listed on the chart below, proceed with other appropriate diagnostics for repair. Reference the appropriate Workshop Manual for assistance. NOTE ALL TRANSMISSIONS WITH SERIAL NUMBERS GREATER THAN THE ONES LISTED BELOW ARE NOT AFFECTED. USE THE CHART BELOW AND THE SAMPLE TAG INFORMATION TO ASSIST IN DETERMINING IF THIS FIX IS APPLICABLE. THE TRANSMISSION SERIAL NUMBER IS LOCATED ON THE TAG ATTACHED TO THE LEFT SIDE OF THE TRANSMISSION. TRANSMISSION SERIAL NUMBER INFORMATION Transmission Application Tag Transmission Serial Number 2.5L I-4 4X2 F87A - AB less than 0629756 3.0L V-6 4X2 F87A - CA less than 0628220 3.0L V-6 4X4 F87A - DA less than D624514 4.0L V-6 4X2 F87A - EA less than D639401 4.0L V-6 4X4 FB7A - FA less than 0627480 1. Drain all fluid from the transmission and remove the transmission following the procedure outlined in the appropriate Workshop Manual. 2. Disassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 3. Inspect the brass blocking rings for any damage. If they are not damaged, reuse on reassembly. 4. Replace the synchronizer. Additionally, replace brass blocking rings if necessary. 5. Reassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 6. Reinstall the transmission and fill with new fluid. Test drive to verify repair. NOTE AFTER THE REPAIR, THE TRANSMISSION MAY FEEL STIFF, ESPECIALLY IF THE BRASS BLOCKING RINGS WERE REPLACED. THIS WILL GO AWAY AFTER DRIVING THE VEHICLE FOR SEVERAL KILOMETERS/MILES, AS THE NEW BLOCKING RINGS NEED TIME TO RESEAT AGAINST THE GEAR CONE. PART NUMBER PART NAME F2TZ-7124-AB Synchronizer Assembly (2.5L And 3.0L) F2TZ-7124-CA Synchronizer Assembly (4.0L) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Hub: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise > Page 6596 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 505000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Ring: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise Synchronizer Ring: Customer Interest M/T - M5OD Buzzing/Grinding Noise Article No. 00-3-6 02/07/00 ^ NOISE - "BUZZING" AND/OR "GRINDING" DURING 2-3 SHIFT - VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 ^ TRANSMISSION - M5OD - "BUZZING" AND/OR "GRINDING" NOISE DURING 2-3 SHIFT VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 FORD: 1998-2000 EXPLORER, RANGER ISSUE Some vehicles may exhibit a "buzzing" and/or "grinding" noise or a "notchy" feeling during the 2-3 upshift. This may be caused by the 3-4 synchronizer. ACTION Replace the 3-4 synchronizer assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE First, verify that vehicle exhibits a buzzing/grinding/notchy feeling/sensation during 2-3 upshift and determine it your transmission serial number is greater than the serial number listed below. If the vehicle does NOT exhibit a buzzing/grinding/notchy feeling/sensation and is greater than the serial number listed on the chart below, proceed with other appropriate diagnostics for repair. Reference the appropriate Workshop Manual for assistance. NOTE ALL TRANSMISSIONS WITH SERIAL NUMBERS GREATER THAN THE ONES LISTED BELOW ARE NOT AFFECTED. USE THE CHART BELOW AND THE SAMPLE TAG INFORMATION TO ASSIST IN DETERMINING IF THIS FIX IS APPLICABLE. THE TRANSMISSION SERIAL NUMBER IS LOCATED ON THE TAG ATTACHED TO THE LEFT SIDE OF THE TRANSMISSION. TRANSMISSION SERIAL NUMBER INFORMATION Transmission Application Tag Transmission Serial Number 2.5L I-4 4X2 F87A - AB less than 0629756 3.0L V-6 4X2 F87A - CA less than 0628220 3.0L V-6 4X4 F87A - DA less than D624514 4.0L V-6 4X2 F87A - EA less than D639401 4.0L V-6 4X4 FB7A - FA less than 0627480 1. Drain all fluid from the transmission and remove the transmission following the procedure outlined in the appropriate Workshop Manual. 2. Disassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 3. Inspect the brass blocking rings for any damage. If they are not damaged, reuse on reassembly. 4. Replace the synchronizer. Additionally, replace brass blocking rings if necessary. 5. Reassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 6. Reinstall the transmission and fill with new fluid. Test drive to verify repair. NOTE AFTER THE REPAIR, THE TRANSMISSION MAY FEEL STIFF, ESPECIALLY IF THE BRASS BLOCKING RINGS WERE REPLACED. THIS WILL GO AWAY AFTER DRIVING THE VEHICLE FOR SEVERAL KILOMETERS/MILES, AS THE NEW BLOCKING RINGS NEED TIME TO RESEAT AGAINST THE GEAR CONE. PART NUMBER PART NAME F2TZ-7124-AB Synchronizer Assembly (2.5L And 3.0L) F2TZ-7124-CA Synchronizer Assembly (4.0L) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Ring: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise > Page 6605 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 505000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Ring: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise Synchronizer Ring: All Technical Service Bulletins M/T - M5OD Buzzing/Grinding Noise Article No. 00-3-6 02/07/00 ^ NOISE - "BUZZING" AND/OR "GRINDING" DURING 2-3 SHIFT - VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 ^ TRANSMISSION - M5OD - "BUZZING" AND/OR "GRINDING" NOISE DURING 2-3 SHIFT VEHICLES EQUIPPED WITH M5OD TRANSMISSION AND BUILT BEFORE 11/1/1999 FORD: 1998-2000 EXPLORER, RANGER ISSUE Some vehicles may exhibit a "buzzing" and/or "grinding" noise or a "notchy" feeling during the 2-3 upshift. This may be caused by the 3-4 synchronizer. ACTION Replace the 3-4 synchronizer assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE First, verify that vehicle exhibits a buzzing/grinding/notchy feeling/sensation during 2-3 upshift and determine it your transmission serial number is greater than the serial number listed below. If the vehicle does NOT exhibit a buzzing/grinding/notchy feeling/sensation and is greater than the serial number listed on the chart below, proceed with other appropriate diagnostics for repair. Reference the appropriate Workshop Manual for assistance. NOTE ALL TRANSMISSIONS WITH SERIAL NUMBERS GREATER THAN THE ONES LISTED BELOW ARE NOT AFFECTED. USE THE CHART BELOW AND THE SAMPLE TAG INFORMATION TO ASSIST IN DETERMINING IF THIS FIX IS APPLICABLE. THE TRANSMISSION SERIAL NUMBER IS LOCATED ON THE TAG ATTACHED TO THE LEFT SIDE OF THE TRANSMISSION. TRANSMISSION SERIAL NUMBER INFORMATION Transmission Application Tag Transmission Serial Number 2.5L I-4 4X2 F87A - AB less than 0629756 3.0L V-6 4X2 F87A - CA less than 0628220 3.0L V-6 4X4 F87A - DA less than D624514 4.0L V-6 4X2 F87A - EA less than D639401 4.0L V-6 4X4 FB7A - FA less than 0627480 1. Drain all fluid from the transmission and remove the transmission following the procedure outlined in the appropriate Workshop Manual. 2. Disassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 3. Inspect the brass blocking rings for any damage. If they are not damaged, reuse on reassembly. 4. Replace the synchronizer. Additionally, replace brass blocking rings if necessary. 5. Reassemble the transmission following the procedure outlined in the appropriate Workshop Manual. 6. Reinstall the transmission and fill with new fluid. Test drive to verify repair. NOTE AFTER THE REPAIR, THE TRANSMISSION MAY FEEL STIFF, ESPECIALLY IF THE BRASS BLOCKING RINGS WERE REPLACED. THIS WILL GO AWAY AFTER DRIVING THE VEHICLE FOR SEVERAL KILOMETERS/MILES, AS THE NEW BLOCKING RINGS NEED TIME TO RESEAT AGAINST THE GEAR CONE. PART NUMBER PART NAME F2TZ-7124-AB Synchronizer Assembly (2.5L And 3.0L) F2TZ-7124-CA Synchronizer Assembly (4.0L) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Ring: > 00-3-6 > Feb > 00 > M/T - M5OD Buzzing/Grinding Noise > Page 6611 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 505000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Technical Service Bulletins > Page 6612 Synchronizer Ring: Specifications Synchronizer Blocking Ring to Gear mm (in) ................................................................................................................................................. 1.5 (0.059) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications Output Shaft: Specifications Output Shaft Maximum Runout mm (in) ....................................................................................................................................................... 0.05 (0.002) Output Shaft Locknut ........................................................................................................................................................ 216-274 Nm (160-202 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Specifications Reverse Idler Gear: Specifications Reverse Idler Gear End Play ........................................................................................................................................ 0.1-0.2 mm (0.0039-0.0078 inch) Reverse Idler Shaft Bolt ........................................................................................................................................................... 79-117 Nm (58-86 ft. lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6623 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 6626 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6629 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6630 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Specifications Shift Fork: Specifications Shift Fork to Synchronizer Sleeve 0.031 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Gearshift Lever Bolt 20 - 29 ft.lb Inner Gearshift Lever Boot Bolts 89 - 123 in.lb Outer Gearshift Lever Boot Screws 45 - 79 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6637 Shifter M/T: Service and Repair Removal 1. Remove the gearshift lever. 1. Lift the outer gearshift lever boot. 2. Remove the bolt. 3. Remove the gearshift lever. 2. Remove the inner gearshift lever boot. 1. Remove the four screws. 2. Remove the inner gearshift lever boot. Installation 1. Install the inner gearshift lever boot. 1. Position the inner gearshift lever boot. 2. Install the screws. 2. Install the gearshift lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6638 1. Position the gearshift lever. 2. Install the bolt. 3. Install the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Transmission Mount Bolts 64 - 81 ft.lb Transmission Mount Nuts 64 - 81 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6645 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 6648 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6651 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6652 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6679 Control Module: Description and Operation The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake depressed and the transmission must be in NEUTRAL. The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect the speed of the front and rear driveshafts. This input is used by the generic electronic module (GEM) primarily to control A4WD operation. The throttle position output signal is provided to the GEM from the powertrain control module (PCM). This signal is used by the GEM in controlling the A4WD clutch. The shift motor sense plate an integral part of the electric shift motor informs the GEM to the position of the transfer case. The digital TR sensors are located on the LH side of the transmission; these sensors inform the GEM when the transmission is in the neutral position. The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the HIGH range (A4WD 4HIGH) and LOW range positions. The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes. The solid state clutch relay is used to activate the A4WD clutch within the transfer case. System Function Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of time the clutch is turned on) which allows for the slight difference between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions the GEM will increase the duty cycle in order to prevent or control slip: ^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position). Feature inputs: ^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch (manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^ Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate position inputs A B C D. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4 shift motor relay outputs. Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature inputs: ^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD mode switch. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6680 ^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated). When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h (3 mph) the brake is applied and the transmission is in NEUTRAL. Feature inputs: ^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^ Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage when brake is depressed open circuit when not activated). ^ Digital transmission range sensor (ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input (manual transmission only). Feature outputs: ^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on baftery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6681 Control Module: Service and Repair AUTOMATIC FOUR WHEEL DRIVE (A4WD) Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives Throttle Position Information From the PCM Only. Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Depower the supplemental restraint system (SRS). 2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc 3. Remove the center instrument panel finish panel. 1. Remove the screws. 2. Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the GEM/CTM. 1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. 2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Four Wheel Drive Selector Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6710 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6711 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6712 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6713 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6714 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6715 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6724 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6725 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6731 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 6732 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 6733 Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 6734 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission > Page 6737 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6740 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6741 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6762 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermistor. It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6767 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 6770 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6773 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 6774 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch > Page 6780 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Four Wheel Drive Selector Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Description and Operation Rotary 4X4 Mode Switch 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch > Page 6799 Four Wheel Drive Selector Switch: Description and Operation Push Button 4X4 Mode Switch Switch, Push Button 4x4 Mode The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the instrument cluster push button, will illuminate only when the 4x4 Low position is engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Service and Repair Rotary 4X4 Mode Switch Mode Select Switch (MSS) Removal and Installation 1. Remove the Mode Select Switch (MSS) knob. 2. Remove the audio unit. 3. Remove the screws and pull the instrument panel center finish panel out of the instrument panel. 4. Disconnect the harness connector, remove the two screws and the MSS. 5. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 6802 Four Wheel Drive Selector Switch: Service and Repair Push Button 4X4 Mode Switch Removal and Installation 1. Remove and reposition the center instrument panel finish panel. 2. Disconnect the 4x4 mode switch electrical connector. 3. Remove the 4x4 mode switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 6803 4. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Transfer case shift motor bolts .............................................................................................................................................................. 10 Nm (89 inch lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6809 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions Transfer Case Actuator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Transfer Case Actuator: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 6827 Transfer Case Actuator: Service and Repair Removal and Installation 1. With the vehicle in the NEUTRAL position, raise and support the vehicle. 2. Remove the heat shield. 3. Disconnect the electrical connector. 4. Remove the coil wire from the electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 6828 1. Remove the connector interlock. 2. Remove the coil wire pin. - Use the proper electrical connector pin remover. 5. Remove the rear output shaft speed sensor. - Carefully remove the sensor from the transfer case. 6. Remove the four bolts and the transfer case shift motor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 6829 7. Remove the front output shaft speed sensor. - Carefully remove the sensor from transfer case. 8. NOTE: Make sure the motor mounting surfaces are clean. Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case. 9. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6838 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6850 Control Module: Description and Operation The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake depressed and the transmission must be in NEUTRAL. The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect the speed of the front and rear driveshafts. This input is used by the generic electronic module (GEM) primarily to control A4WD operation. The throttle position output signal is provided to the GEM from the powertrain control module (PCM). This signal is used by the GEM in controlling the A4WD clutch. The shift motor sense plate an integral part of the electric shift motor informs the GEM to the position of the transfer case. The digital TR sensors are located on the LH side of the transmission; these sensors inform the GEM when the transmission is in the neutral position. The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the HIGH range (A4WD 4HIGH) and LOW range positions. The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes. The solid state clutch relay is used to activate the A4WD clutch within the transfer case. System Function Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of time the clutch is turned on) which allows for the slight difference between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions the GEM will increase the duty cycle in order to prevent or control slip: ^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position). Feature inputs: ^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch (manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^ Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate position inputs A B C D. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4 shift motor relay outputs. Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature inputs: ^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD mode switch. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6851 ^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated). When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h (3 mph) the brake is applied and the transmission is in NEUTRAL. Feature inputs: ^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^ Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage when brake is depressed open circuit when not activated). ^ Digital transmission range sensor (ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input (manual transmission only). Feature outputs: ^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on baftery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6852 Control Module: Service and Repair AUTOMATIC FOUR WHEEL DRIVE (A4WD) Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives Throttle Position Information From the PCM Only. Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Depower the supplemental restraint system (SRS). 2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc 3. Remove the center instrument panel finish panel. 1. Remove the screws. 2. Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the GEM/CTM. 1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. 2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks Fluid - Transfer Case: Customer Interest Front Axle - Vent Tube Fluid Leaks Article No. 01-8-6 4/30/01 ^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD ^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 EXPLORER 1997-2001 RANGER MERCURY: 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model applications and model years. ISSUE Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the Instruction Sheet included in the kit and the following text for details. The Cover Kit (F6TZ-4033-BA) includes the following: ^ One (1) Cover One (1) Hose ^ One (1) Hose Connector One (1) Vent Plug One (1) Clip ^ One (1) Sealant ^ One (1) Instruction Sheet NOTE SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 010806A Install Axle Cover kit 1.7 Hrs. DEALER CODING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks > Page 6861 CONDITION BASIC PART NO. CODE 4022 D1 OASIS CODES: 509000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks Fluid - Transfer Case: All Technical Service Bulletins Front Axle - Vent Tube Fluid Leaks Article No. 01-8-6 4/30/01 ^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD ^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 EXPLORER 1997-2001 RANGER MERCURY: 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model applications and model years. ISSUE Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the Instruction Sheet included in the kit and the following text for details. The Cover Kit (F6TZ-4033-BA) includes the following: ^ One (1) Cover One (1) Hose ^ One (1) Hose Connector One (1) Vent Plug One (1) Clip ^ One (1) Sealant ^ One (1) Instruction Sheet NOTE SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 010806A Install Axle Cover kit 1.7 Hrs. DEALER CODING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks > Page 6867 CONDITION BASIC PART NO. CODE 4022 D1 OASIS CODES: 509000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... ...................................................................... 3.0 Pints Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 6870 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 Four Wheel Drive Selector Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch > Page 6898 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 Four Wheel Drive Selector Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Description and Operation Rotary 4X4 Mode Switch 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch > Page 6917 Four Wheel Drive Selector Switch: Description and Operation Push Button 4X4 Mode Switch Switch, Push Button 4x4 Mode The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the instrument cluster push button, will illuminate only when the 4x4 Low position is engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Service and Repair Rotary 4X4 Mode Switch Mode Select Switch (MSS) Removal and Installation 1. Remove the Mode Select Switch (MSS) knob. 2. Remove the audio unit. 3. Remove the screws and pull the instrument panel center finish panel out of the instrument panel. 4. Disconnect the harness connector, remove the two screws and the MSS. 5. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 6920 Four Wheel Drive Selector Switch: Service and Repair Push Button 4X4 Mode Switch Removal and Installation 1. Remove and reposition the center instrument panel finish panel. 2. Disconnect the 4x4 mode switch electrical connector. 3. Remove the 4x4 mode switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 6921 4. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6947 Control Module: Description and Operation The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake depressed and the transmission must be in NEUTRAL. The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect the speed of the front and rear driveshafts. This input is used by the generic electronic module (GEM) primarily to control A4WD operation. The throttle position output signal is provided to the GEM from the powertrain control module (PCM). This signal is used by the GEM in controlling the A4WD clutch. The shift motor sense plate an integral part of the electric shift motor informs the GEM to the position of the transfer case. The digital TR sensors are located on the LH side of the transmission; these sensors inform the GEM when the transmission is in the neutral position. The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the HIGH range (A4WD 4HIGH) and LOW range positions. The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes. The solid state clutch relay is used to activate the A4WD clutch within the transfer case. System Function Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of time the clutch is turned on) which allows for the slight difference between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions the GEM will increase the duty cycle in order to prevent or control slip: ^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position). Feature inputs: ^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch (manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^ Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate position inputs A B C D. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4 shift motor relay outputs. Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature inputs: ^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD mode switch. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6948 ^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated). When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h (3 mph) the brake is applied and the transmission is in NEUTRAL. Feature inputs: ^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^ Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage when brake is depressed open circuit when not activated). ^ Digital transmission range sensor (ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input (manual transmission only). Feature outputs: ^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on baftery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6949 Control Module: Service and Repair AUTOMATIC FOUR WHEEL DRIVE (A4WD) Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives Throttle Position Information From the PCM Only. Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Depower the supplemental restraint system (SRS). 2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc 3. Remove the center instrument panel finish panel. 1. Remove the screws. 2. Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the GEM/CTM. 1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. 2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Four Wheel Drive Selector Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair Seals and Gaskets: Service and Repair Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. With the transmission in neutral, raise and support the vehicle. 2. Index-mark the rear output flange and the driveshaft yoke. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 6973 3. Remove the four bolls. 4. Separate the driveshaft from the output flange, and position the driveshaft aside. 5. Index-mark the rear output flange to the rear output shaft. 6. Use the special tool to hold the rear output flange while removing the nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 6974 7. Remove the rear output flange. 1. Remove the output shaft yoke washer. 2. Remove the oil seal. 3. Remove the rear output flange. 8. Using the special tools, remove the oil seal. Installation 1. To install, reverse the removal procedure. - Use the special tool to install the oil seal. - Check, and if necessary, fill the transfer case to the specified level with the specified fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch > Page 6980 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 Four Wheel Drive Selector Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Description and Operation Rotary 4X4 Mode Switch 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch > Page 6999 Four Wheel Drive Selector Switch: Description and Operation Push Button 4X4 Mode Switch Switch, Push Button 4x4 Mode The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the instrument cluster push button, will illuminate only when the 4x4 Low position is engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Service and Repair Rotary 4X4 Mode Switch Mode Select Switch (MSS) Removal and Installation 1. Remove the Mode Select Switch (MSS) knob. 2. Remove the audio unit. 3. Remove the screws and pull the instrument panel center finish panel out of the instrument panel. 4. Disconnect the harness connector, remove the two screws and the MSS. 5. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 7002 Four Wheel Drive Selector Switch: Service and Repair Push Button 4X4 Mode Switch Removal and Installation 1. Remove and reposition the center instrument panel finish panel. 2. Disconnect the 4x4 mode switch electrical connector. 3. Remove the 4x4 mode switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 7003 4. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Transfer case shift motor bolts .............................................................................................................................................................. 10 Nm (89 inch lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7007 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions Transfer Case Actuator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Transfer Case Actuator: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7025 Transfer Case Actuator: Service and Repair Removal and Installation 1. With the vehicle in the NEUTRAL position, raise and support the vehicle. 2. Remove the heat shield. 3. Disconnect the electrical connector. 4. Remove the coil wire from the electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7026 1. Remove the connector interlock. 2. Remove the coil wire pin. - Use the proper electrical connector pin remover. 5. Remove the rear output shaft speed sensor. - Carefully remove the sensor from the transfer case. 6. Remove the four bolts and the transfer case shift motor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7027 7. Remove the front output shaft speed sensor. - Carefully remove the sensor from transfer case. 8. NOTE: Make sure the motor mounting surfaces are clean. Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case. 9. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information > Technical Service Bulletins > Customer Interest for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks Transfer Case Cover: Customer Interest Front Axle - Vent Tube Fluid Leaks Article No. 01-8-6 4/30/01 ^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD ^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 EXPLORER 1997-2001 RANGER MERCURY: 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model applications and model years. ISSUE Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the Instruction Sheet included in the kit and the following text for details. The Cover Kit (F6TZ-4033-BA) includes the following: ^ One (1) Cover One (1) Hose ^ One (1) Hose Connector One (1) Vent Plug One (1) Clip ^ One (1) Sealant ^ One (1) Instruction Sheet NOTE SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 010806A Install Axle Cover kit 1.7 Hrs. DEALER CODING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information > Technical Service Bulletins > Customer Interest for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks > Page 7036 CONDITION BASIC PART NO. CODE 4022 D1 OASIS CODES: 509000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks Transfer Case Cover: All Technical Service Bulletins Front Axle - Vent Tube Fluid Leaks Article No. 01-8-6 4/30/01 ^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD ^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 EXPLORER 1997-2001 RANGER MERCURY: 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model applications and model years. ISSUE Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the Instruction Sheet included in the kit and the following text for details. The Cover Kit (F6TZ-4033-BA) includes the following: ^ One (1) Cover One (1) Hose ^ One (1) Hose Connector One (1) Vent Plug One (1) Clip ^ One (1) Sealant ^ One (1) Instruction Sheet NOTE SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 010806A Install Axle Cover kit 1.7 Hrs. DEALER CODING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks > Page 7042 CONDITION BASIC PART NO. CODE 4022 D1 OASIS CODES: 509000, 510000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 1. Shift solenoid A & B. 2. Torque Converter Clutch solenoid 3. Electronic Pressure Control Solenoid. 4. Bulkhead inter-connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 7066 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid regulates transmission pressure. EPC valve pressure is used to control line pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 7067 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 7068 1. Disconnect the shift solenoid SSA and SSB. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. 1. Remove the bolt and EPC solenoid bracket. 2. Remove the EPC solenoid. Installation 1. Install the EPC solenoid. 1. Install the EPC solenoid. 2. Install the EPC solenoid bracket and bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 7069 2. Inspect the lead frame for damage. - Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. - If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. - Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 7070 through the connector slots. - Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. - Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4. Install the manual control lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 7074 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 7095 Shift Solenoid: Description and Operation Shift Solenoid SSA, SSB Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the pressure to the three shift valves. One unit containing the two shift solenoids is located in the main control valve body. The shift solenoids are two-way normally open style. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 7099 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 7117 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Transfer case shift motor bolts .............................................................................................................................................................. 10 Nm (89 inch lbs.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7122 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions Transfer Case Actuator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 Transfer Case Actuator: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7140 Transfer Case Actuator: Service and Repair Removal and Installation 1. With the vehicle in the NEUTRAL position, raise and support the vehicle. 2. Remove the heat shield. 3. Disconnect the electrical connector. 4. Remove the coil wire from the electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7141 1. Remove the connector interlock. 2. Remove the coil wire pin. - Use the proper electrical connector pin remover. 5. Remove the rear output shaft speed sensor. - Carefully remove the sensor from the transfer case. 6. Remove the four bolts and the transfer case shift motor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7142 7. Remove the front output shaft speed sensor. - Carefully remove the sensor from transfer case. 8. NOTE: Make sure the motor mounting surfaces are clean. Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case. 9. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 7148 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 7152 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 7183 Control Module: Description and Operation The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake depressed and the transmission must be in NEUTRAL. The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect the speed of the front and rear driveshafts. This input is used by the generic electronic module (GEM) primarily to control A4WD operation. The throttle position output signal is provided to the GEM from the powertrain control module (PCM). This signal is used by the GEM in controlling the A4WD clutch. The shift motor sense plate an integral part of the electric shift motor informs the GEM to the position of the transfer case. The digital TR sensors are located on the LH side of the transmission; these sensors inform the GEM when the transmission is in the neutral position. The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the HIGH range (A4WD 4HIGH) and LOW range positions. The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes. The solid state clutch relay is used to activate the A4WD clutch within the transfer case. System Function Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of time the clutch is turned on) which allows for the slight difference between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions the GEM will increase the duty cycle in order to prevent or control slip: ^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position). Feature inputs: ^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch (manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^ Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate position inputs A B C D. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4 shift motor relay outputs. Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature inputs: ^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD mode switch. Feature outputs: ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 7184 ^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated). When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h (3 mph) the brake is applied and the transmission is in NEUTRAL. Feature inputs: ^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^ Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage when brake is depressed open circuit when not activated). ^ Digital transmission range sensor (ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input (manual transmission only). Feature outputs: ^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on baftery potential when relay is off). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 7185 Control Module: Service and Repair AUTOMATIC FOUR WHEEL DRIVE (A4WD) Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives Throttle Position Information From the PCM Only. Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Depower the supplemental restraint system (SRS). 2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc 3. Remove the center instrument panel finish panel. 1. Remove the screws. 2. Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the GEM/CTM. 1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. 2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 Four Wheel Drive Selector Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7214 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7215 Digital Transmission Range Sensor: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7216 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7217 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1. Remove the nut. 2. Remove the lever. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7218 6. Loosen the digital TR bolts. 7. Note: Manual shift lever must be in the neutral position. Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1. Position the manual control lever. 2. Install a new manual lever shaft outer nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7219 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: Customer Interest A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 7228 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T - MIL Flashing, DTC'S P0741 And P1728 Set > Page 7229 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T MIL Flashing, DTC'S P0741 And P1728 Set Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL Flashing, DTC'S P0741 And P1728 Set Article No. 01-5-4 March 19, 2001 ^ ELECTRICAL - LAMP - TRANSMISSION CONTROL ^ INDICATOR LAMP (TCIL) ILLUMINATED ^ DIAGNOSTIC TROUBLE CODE (DTC) P0141 ^ AND/OR P1728 - VEHICLES EQUIPPED WITH 5.0L ^ ENGINE AND 4R70W TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - TRANSMISSION ^ CONTROL INDICATOR LAMP (TCIL) ^ ILLUMINATED - DIAGNOSTIC TROUBLE CODE ^ (DTC) P0741 AND/OR P1728 - VEHICLES EQUIPPED ^ WITH 5.0L ENGINE AND 4R70W TRANSMISSION ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles may exhibit a flashing Transmission Control Indicator Lamp (TCIL) accompanied by a Diagnostic Trouble Code (DTC) P0741 and in some cases P1728. This may be caused by the Output Shaft Speed Sensor (OSS) signal being improperly processed by the Powertrain Control Module (PCM). ACTION Retrieve DTCs. Verify DTC P0741 and in some cases P1728. Diagnose and reprogram the PCM if necessary. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify transmission fluid levels (and transfer case level if equipped). 2. Verify that DTC P0741 and in some cases P1728 are present. If other DTCs are present, repair them first. 3. Follow the Output State Control (OSC) procedures for both bench and drive modes as listed in the appropriate model year Workshop Manual (Section 307-1A) to verify transmission and solenoid operation. While in OSC drive mode, monitor OSS Sensor - OSS PID for proper signal as stated in the Workshop Manual. This will verify OSS operation. If the solenoids or transmission fail to perform properly, follow normal diagnosis and repair procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T MIL Flashing, DTC'S P0741 And P1728 Set > Page 7235 4. Reprogram the PCM following the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual. Refer to the PCM Calibration Information Chart shown. 5. Verify the repair following the Transmission Drive Cycle test as written in the appropriate model year Workshop Manual. (Section 307-1A). NOTE: THE TRANSMISSION DRIVE CYCLE TEST MUST BE PERFORMED EXACTLY AS WRITTEN. DO NOT SHORT CUT OR MISS ANY STEPS OR THE PROCEDURE WILL NOT BE ABLE TO VALIDATE THE REPAIR. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 01-5-4 > Mar > 01 > A/T MIL Flashing, DTC'S P0741 And P1728 Set > Page 7236 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Information ONLY OASIS CODES: 204000, 206000, 504000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 7237 Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 7238 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > 4R70W Transmission > Page 7241 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 7244 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 7245 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 Diagram 30-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 7266 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift solenoids on the main control valve body. It is a temperature sensitive device called a thermistor. It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC) operation at low transmission fluid temperatures and corrects electronic pressure control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 9 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 7271 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 7274 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 7277 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Output Shaft Speed Sensor-Front > Page 7278 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Rotary 4X4 Mode Switch > Page 7284 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Selector Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7291 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7292 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7293 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 Four Wheel Drive Selector Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7296 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7297 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7299 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Description and Operation Rotary 4X4 Mode Switch 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > Rotary 4X4 Mode Switch > Page 7303 Four Wheel Drive Selector Switch: Description and Operation Push Button 4X4 Mode Switch Switch, Push Button 4x4 Mode The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the instrument cluster push button, will illuminate only when the 4x4 Low position is engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch Four Wheel Drive Selector Switch: Service and Repair Rotary 4X4 Mode Switch Mode Select Switch (MSS) Removal and Installation 1. Remove the Mode Select Switch (MSS) knob. 2. Remove the audio unit. 3. Remove the screws and pull the instrument panel center finish panel out of the instrument panel. 4. Disconnect the harness connector, remove the two screws and the MSS. 5. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 7306 Four Wheel Drive Selector Switch: Service and Repair Push Button 4X4 Mode Switch Removal and Installation 1. Remove and reposition the center instrument panel finish panel. 2. Disconnect the 4x4 mode switch electrical connector. 3. Remove the 4x4 mode switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Rotary 4X4 Mode Switch > Page 7307 4. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 7313 ABS Light: Description and Operation The Antilock Brake System (ABS) uses the yellow ABS warning indicator to alert the driver of a malfunctions in the ABS. The yellow ABS warning indicator will come on to warn the driver that the ABS has been turned off due to a symptom that exists in the ABS. Normal power assist braking remains but wheels can lock during a panic stop while the yellow ABS warning indicator is illuminated. The diagnostic procedures must be followed step-by-step in order to correct the condition. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Locations > Page 7317 Acceleration/Deceleration Sensor: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the nuts. 3. Unclip the fuel filter from the vehicle frame. 4. Remove the G-switch. 1 Disconnect the G-switch electrical connector. 2 Remove the G-switch. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Locations > Page 7318 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Electronic Brake Control Module: Customer Interest Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 7330 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Electronic Brake Control Module: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 7336 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 7342 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 7343 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 7344 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 7350 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 7351 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 7352 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7353 Electronic Brake Control Module: Specifications Anti-lock brake control module bolts 1.8 - 1.9 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7354 Electronic Brake Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7355 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7356 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7357 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7358 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the scan tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7359 1. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake line to (EHCU) nuts (M10-1) 12-16 ft.lb Brake line to (EHCU) nuts (M12-1) 15-18 ft.lb Electronic hydraulic control unit bolts 9-13 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7363 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7364 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. Remove the anti-lock brake control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7365 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: After the HCU is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 7369 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Remove the rotor shield. 2. Disconnect the front anti-lock brake sensor electrical connector. 3. Unclip the front anti-lock brake sensor wire from the vehicle frame. 4. Remove the bolt. 5. Remove the front anti-lock brake sensor. 1 Remove the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 7372 2 Remove the front anti-lock brake sensor. Installation 1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 7373 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Caliper bleeder screw, rear 15 ft.lb Caliper bleeder screw, front 15 ft.lb Master cylinder bleeder screw 70-159 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7379 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7380 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7381 Brake Bleeding: Service and Repair Brake System Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7382 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed procedure as outlined in Steps 3 - 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7383 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been installed new or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7384 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, remove the cruise switch. 5. Fill the cruise switch with the specified brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7385 6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles are seen in the expelled brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7386 14. Repeat the above four steps for the remaining master cylinder outlet tube. 15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 16. Have an assistant pump and then hold firm pressure on the brake pedal. 17. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 20. Bleed the brake system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 7387 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake pedal bracket bolts and nuts 16 - 21 ft.lb Brake pedal bracket nuts 16 - 21 ft.lb Brake pedal pivot bolt and nut 15 - 25 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7391 Brake Pedal Assy: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brakes and Traction Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7392 Brake Pedal Assy: Service and Repair Removal 1. NOTE: When removing the stoplight switch, retain the bushing and hairpin clip. They will be required for installation. Disconnect the brake booster push rod. 1 Remove the hairpin clip. 2 Separate the stoplight switch and the brake booster push rod from the brake pedal pin. 3 Remove the brake booster push rod bushing. 2. Remove the bulkhead sound insulator. 3. Remove the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7393 4. CAUTION: Support the brake master cylinder and power brake booster in the engine compartment. Remove the brake pedal assembly. 1 Remove the nuts. 2 Remove the brake pedal assembly. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7394 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 7398 Brake Warning Indicator: Description and Operation Brake System The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction or a parking brake that is not fully released. The brake fluid level switch is located in the brake fluid reservoir. The yellow brake warning indicator is used to indicate a malfunction or deactivation of the Anti-lock Brake System (ABS). It illuminates when triggered by the ABS control module and stays illuminated as long as the malfunction remains in the system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Front disc brake caliper anchor plate bolts 72 - 97 ft.lb Disc brake caliper bolts 21 - 26 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front > Page 7404 Brake Caliper: Specifications Brake caliper bolts 20 ft.lb Caliper flow bolt 23-29 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle, This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7407 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Inspect the brake system operation. Caliper Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7408 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7409 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Removal 1. NOTE: AWD and 4x4 shown, 4x2 similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7410 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7411 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. ^ Use new copper washers. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7412 Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7413 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7414 Rear Disc Brake Adapter Removal 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum thickness above the metal backing plate or rivets 0.10 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Install a new pad if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 5. Remove the lower caliper bolt. 6. Rotate the disc brake caliper upward. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7420 7. Remove the pads and the stainless slippers. 1 Remove the pads. 2 Remove the stainless slippers. 8. On 4x2 vehicles, measure the brake disc and hub for minimum thickness. ^ Machine the brake disc first then, install a new brake disc and hub if not within specification. 9. On 4x4 vehicles, measure the brake disc for minimum thickness and for lateral runout. ^ Machine the brake disc first then, install a new brake disc if not within specification. 10. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7421 1. NOTE: Use a suitable suction device to remove brake fluid from the master cylinder. NOTE: Clean the anchor plate and stainless slipper surfaces. NOTE: The inboard pad has a wear indicator tab. Install the stainless slippers and the pads. 1 Install the stainless slippers. 2 Install the pads. 2. Inspect the anti-rattle spring, install a new spring if worn or damaged. 3. NOTE: If installing new pads, the caliper pistons must be compressed using a C-clamp and a wooden block. Lower the brake fluid level in the master cylinder if required. Rotate the disc brake caliper downward. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7422 4. Install the caliper bolt. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 6. Inspect the brake system operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7423 Brake Pad: Service and Repair Rear Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. CAUTION: Replace the pads if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. Install new pads if worn to or past specification. 3. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure. Remove the rear disc brake caliper. 4. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads. 5. Retract the caliper piston into the rear disc brake caliper. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7424 6. Remove the slippers. 7. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification. Installation 1. Clean the slipper mating surface, and install the slippers. 2. CAUTION: Install new brake pads in full axle sets. Do not install new brake pads on only one side of vehicle. Install the brake pads. 3. Install the rear disc brake caliper. 4. Verify correct brake operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc .............................................................................................................................................................. ........................................................ Min Thickness Front .................................................................................................................................................... ............................................. 0.9646 inch (24.50mm) Rear ..................................................................................................................................................... .................................................. 0.4331 inch (11mm) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 7429 Brake Rotor/Disc: Specifications Brake disc shield bolts 7-10 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Brake Disc Removal 1. Remove the front disc brake caliper anchor plate. 2. On 4x4 vehicles, remove the brake disc. 3. On 4x2 vehicles, remove the brake disc and hub as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the brake disc and hub. 4. Remove the wheel hub grease seal. Remove the front wheel bearing. Installation 1. On AWD and 4x4 vehicles, position the brake disc to the wheel hub. Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc. 2. On 4x2 vehicles, thoroughly clean and inspect the front wheel bearings and the brake disc and hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 7432 ^ Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent. 3. On 4x2 vehicles, lubricate the front wheel bearings. ^ Use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford specification ESA-M1C75-B. 4. On 4x2 vehicles, install a new wheel hub grease seal. 1 Install the inner front wheel bearing. 2 Install a new wheel hub grease seal. 5. On 4x2 vehicles, install the brake disc and hub. 1 Position the brake disc and hub. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 6. Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 7433 7. Loosen the spindle nut. 8. Tighten the spindle nut while rotating the brake disc and hub. 9. On 4x2 vehicles, install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. 10. Install the front disc brake caliper anchor plate. Brake Disc Shield Removal 1. Remove the brake disc. 2. Remove the brake disc shield. ^ Remove the three brake disc shield bolts and remove the brake disc shield. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 7434 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 7435 Brake Rotor/Disc: Service and Repair Rear Brake Disc Removal 1. NOTE: When removing the rear brake disc in this procedure it is not necessary to disconnect the hydraulic lines. Remove the rear disc brake caliper. 2. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and contract the parking brake shoe and lining. Remove the rear brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification. Installation 1. Follow the removal procedure in reverse order. Brake Disc Shield Removal 1. Remove the rear wheel disc brake adapter. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 7436 2. Remove the rear wheel disc brake shield. 1 Drill out the rivet. 2 Remove the rear wheel disc brake shield. Installation 1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, a new rivet is not required. Seal the rivet hole with Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Caliper bleeder screw, rear 15 ft.lb Caliper bleeder screw, front 15 ft.lb Master cylinder bleeder screw 70-159 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7443 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7444 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7445 Brake Bleeding: Service and Repair Brake System Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7446 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed procedure as outlined in Steps 3 - 7. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7447 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been installed new or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7448 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, remove the cruise switch. 5. Fill the cruise switch with the specified brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7449 6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles are seen in the expelled brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 7450 14. Repeat the above four steps for the remaining master cylinder outlet tube. 15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 16. Have an assistant pump and then hold firm pressure on the brake pedal. 17. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 20. Bleed the brake system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 7451 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Front disc brake caliper anchor plate bolts 72 - 97 ft.lb Disc brake caliper bolts 21 - 26 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front > Page 7456 Brake Caliper: Specifications Brake caliper bolts 20 ft.lb Caliper flow bolt 23-29 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle, This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7459 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Inspect the brake system operation. Caliper Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7460 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7461 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Removal 1. NOTE: AWD and 4x4 shown, 4x2 similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7462 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7463 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. ^ Use new copper washers. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7464 Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7465 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7466 Rear Disc Brake Adapter Removal 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 7470 Brake Fluid: Description and Operation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. ^ Do not mix different types of brake fluid. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7474 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake pressure switch 11-14 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Front brake hose bolt 23-29 ft.lb Front brake hose bracket 10-12 ft.lb Front brake tube 12-14 ft.lb Rear brake hose to caliper bolt 23 - 29 ft.lb Brake hose bracket to rear axle bolt 10 - 12 ft.lb Rear brake tube fitting 12 - 14 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7481 Brake Hose/Line: Service and Repair CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which could result in brake tube failure. If a section of brake tube is damaged, the entire section must be installed new with a tube of the same type, size, shape and length. When installing hydraulic brake tubing, hoses, or connectors, tighten all connections to specifications. After installation, bleed the brake system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Brake pressure control valve 10 - 16 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake line to (EHCU) nuts (M10-1) 12-16 ft.lb Brake line to (EHCU) nuts (M12-1) 15-18 ft.lb Electronic hydraulic control unit bolts 9-13 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7488 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7489 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. Remove the anti-lock brake control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7490 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: After the HCU is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder Brake Master Cylinder: Specifications Brake master cylinder nut 14 - 19 ft.lb Master cylinder brake tube nuts 12 - 14 ft.lb Master cylinder bleeder screw 6 - 13 ft.lb Brake master cylinder tube fitting, front 11 - 14 ft.lb Brake master cylinder tube fitting, rear 11 - 14 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder > Page 7495 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7496 Brake Master Cylinder: Description and Operation The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. The following conditions are considered normal and not indications that the brake master cylinder is in need of repair or replacement: ^ Low brake fluid level detected without signs of leakage. This condition is caused by displacement of brake fluid from the brake master cylinder reservoir into the disc brake calipers/rear disc brake calipers to compensate for normal brake wear. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ A momentary or slight squirt of brake fluid inside the brake master cylinder reservoir upon application of the brake pedal. ^ A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > General Procedures Brake Master Cylinder: Testing and Inspection General Procedures Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the Symptom Chart at Brakes and Traction Control/Testing and Inspection for abnormal condition diagnosis. Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or installed new. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > General Procedures > Page 7499 Brake Master Cylinder: Testing and Inspection Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 7500 Brake Master Cylinder: Adjustments Master Cylinder Push Rod Adjustment 1. Remove the brake master cylinder. 2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster. Adjust the power brake booster to brake master cylinder push rod, vacuum applied. 1 Measure the power brake booster to brake master cylinder push rod. 2 If necessary, adjust the screw to the correct length. 3. Install the brake master cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the brake fluid level warning switch. 2. On cruise control equipped vehicles, disconnect the brake pressure switch. 3. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports. 4. On vehicles with 4.0L engine, remove the wiring retainer clip from the master cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 7503 5. Remove the brake master cylinder. 1 Remove the nuts. 2 Remove the brake master cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Bleed the brake master cylinder before installation. ^ Bleed the brake system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 7504 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Carefully pry up on the brake master cylinder reservoir to remove. Installation 1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it snaps. 3 Connect the brake master cylinder fluid level warning switch. 4 Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Torque Specifications Parking brake cable and conduit clip bolt ..................................................................................................................................... 15-20 Nm (11-14 lb.ft) Parking brake cable retainer clip bolt .............................................................................................................................................. 6-8 Nm (54-70 in.lb) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front Parking Brake Cable: Service and Repair Cable and Conduit - Front Removal 1. Remove the parking brake control. 2. Disconnect the front parking brake cable from the parking brake control. 3. Remove the front parking brake cable and conduit housing. 1 Compress the front parking brake cable and conduit-to-parking brake control clip. 2 Remove the front parking brake cable and conduit housing. Installation 1. Follow the removal procedure in reverse order. ^ Make sure cable is routed through loop on take up spool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 7511 Parking Brake Cable: Service and Repair Cable and Conduit - Rear Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. NOTE: Disconnect the parking brake intermediate cable from the locating hole end of the connector. Disconnect the parking brake intermediate cable from the LH parking brake rear cable and conduit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 7512 5. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. 6. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket 1 Compress the parking brake cable clip. 2 Remove the RH parking brake rear cable and conduit from the parking brake cable bracket. 7. Remove the RH parking brake rear cable and conduit to LH parking brake rear cable and conduit clip. 8. Remove the RH parking brake rear cable and conduit from the rear parking brake cable retainer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 7513 9. Remove the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. 10. Remove the parking brake cable retainer clip. 1 Remove the parking brake cable retainer clip bolt. 2 Remove the parking brake cable retainer clip. 11. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle housing. 12. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 7514 13. Unclip the parking brake rear cable and conduit from the parking brake lever. Installation 1. Clip the parking brake rear cable and conduit to the parking brake lever. 2. Connect the parking brake rear cable and conduit to the rear disc brake caliper anchor plate. 3. Clip the parking brake rear cable and conduit to the brake line clip on top of the rear axle housing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 7515 4. Install the parking brake cable retainer clip. 1 Position the parking brake cable retainer clip. 2 Install the parking brake cable retainer clip bolt. 5. Install the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. 6. Hook the RH parking brake rear cable and conduit to the rear parking brake cable retainer. 7. Install the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 7516 8. Connect the RH parking brake rear cable and conduit to the parking brake cable bracket. 1 Install the RH parking brake rear cable and conduit to the parking brake cable bracket. 2 Push the RH parking brake rear cable and conduit into the parking brake cable bracket until the parking brake cable and conduit clip is seated. 9. Connect the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit at the parking brake cable equalizer. 10. Connect the parking brake intermediate cable to the LH parking brake rear cable and conduit. 11. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the front wheel and tire assemblies. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 7517 12. Apply tension to the parking brake system. 1 Pull down on the front parking brake cable and conduit. 2 Remove the retainer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Torque Specifications Parking brake control bolts .............................................................................. ................................................................................. 17-23 Nm (13-17 lb.ft) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7521 Parking Brake Control: Service and Repair Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull down on the parking brake intermediate cable. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer in the parking brake control. 2. Remove the LH front fender apron. 3. Remove the front parking brake cable and conduit from the retainer clip. 1 Remove the front parking brake cable and conduit retainer clip bolt. 2 Remove the front parking brake cable and conduit retainer clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7522 4. NOTE: Disconnect the front parking brake cable and conduit at the locating hole end of the connector. Disconnect the front parking brake cable and conduit from the parking brake intermediate cable. 5. Remove the front parking brake cable and conduit from the bracket. 1 Compress the retainer from the front parking brake cable and conduit from the bracket. 2 Remove the front parking brake cable and conduit from the bracket. 6. Remove the parking brake release mounting bolts. 7. Remove the parking brake control and front parking brake cable and conduit. 1 Disconnect the parking brake signal switch electrical connector. 2 Remove the three parking brake control bolts. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7523 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel ......................................................................................................................... 2.1-2.9 Nm (19-25 ft. lbs) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications Parking Brake Shoe: Specifications Parking brake shoes and lining minimum thickness 0.04 ft Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 7530 Parking Brake Shoe: Service and Repair Special Service Tool(s) Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the tire and wheel assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 7531 4. Remove the rear brake disc. 5. Remove the brake shoe retracting spring. 6. Remove the brake shoe adjusting screw spring. 7. Remove the brake adjuster screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 7532 8. Remove the rear brake shoe hold-down springs. 9. Remove the rear brake shoes and linings along with the inboard brake shoe retracting spring. 10. Inspect the components for excessive wear or damage and install new as required. Installation 1. NOTE: Lubricate the brake shoe contact point before installation of rear shoes using Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford Specification ESE-M1C171-A. Install the rear brake shoes and linings along with the inboard brake shoe retracting spring. 2. Install the brake shoe hold-down springs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 7533 3. Install the brake adjuster screw. 4. Install the brake shoe adjusting screw spring. 5. Install the outboard brake shoe retracting spring. 6. Use Brake Adjusting Gauge to measure the inside diameter of the drum portion of the rear brake disc. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 7534 7. Use Brake Adjusting Gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020 inch) less than the inside diameter of the drum portion of the rear brake disc. 8. Install the rear brake disc. 9. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 10. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 7535 11. Apply tension to the parking brake cable system. 1 Hold the front parking brake cable and conduit taut. 2 Remove the retainer from the parking brake control. 12. Check the operation of the parking brake. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 7536 Special Tools Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power brake booster push rod length 0.99 - 1.01 in Power brake booster nuts 15 - 20 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 7541 Vacuum Brake Booster: Description and Operation The power brake booster: ^ is a dual diaphragm, vacuum assisted power brake booster. ^ is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. ^ is divided into separate chambers by the diaphragm. ^ will not operate if vacuum is restricted or if any of the vacuum related power brake components fail. ^ is installed as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Brake Booster - Operational Check Vacuum Brake Booster: Testing and Inspection Brake Booster - Operational Check 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Continue the test with the following steps. 4. Remove the vacuum booster hose from check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster, connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2 and 3 above. 5. Check and if no downward movement of the brake pedal is felt, install a new power brake booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 Nm (20 lbs.) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Brake Booster - Operational Check > Page 7544 Vacuum Brake Booster: Testing and Inspection Vacuum Connection Checks Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be correctly secured and in good condition with no holes, soft or collapsed areas. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7545 Vacuum Brake Booster: Service and Repair Removal 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1 Compress the clamp. 2 Disconnect the power brake booster hose. 3. Disconnect the brake pedal to power brake booster push rod. 1 Remove the self-locking pin. 2 Remove the stoplight switch and the brake booster push rod from the brake pedal pin. 3 Remove the brake booster push rod bushing. 4. Remove the bulkhead sound insulator. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7546 5. NOTE: Support the power brake booster. Remove the power brake booster. 1 Remove the nuts. 2 Remove the power brake booster. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation The power brake booster check valve: ^ is located on the front of the power brake booster. ^ is positioned between the power brake booster and the power brake booster hose. ^ closes when the engine is turned off. ^ in the closed position, traps engine vacuum in the power brake booster. ^ retains vacuum to provide several power assisted brake applications with the engine off. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 7550 Vacuum Brake Booster Check Valve: Testing and Inspection The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve: ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power brake booster check valve from the power brake booster. ^ There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Electronic Brake Control Module: Customer Interest Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 7560 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Electronic Brake Control Module: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 7566 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7567 Electronic Brake Control Module: Specifications Anti-lock brake control module bolts 1.8 - 1.9 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7568 Electronic Brake Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7569 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7570 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7571 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7572 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the scan tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7573 1. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations > Page 7578 Acceleration/Deceleration Sensor: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the nuts. 3. Unclip the fuel filter from the vehicle frame. 4. Remove the G-switch. 1 Disconnect the G-switch electrical connector. 2 Remove the G-switch. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations > Page 7579 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7583 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake pressure switch 11-14 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel ......................................................................................................................... 2.1-2.9 Nm (19-25 ft. lbs) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 7596 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Remove the rotor shield. 2. Disconnect the front anti-lock brake sensor electrical connector. 3. Unclip the front anti-lock brake sensor wire from the vehicle frame. 4. Remove the bolt. 5. Remove the front anti-lock brake sensor. 1 Remove the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 7599 2 Remove the front anti-lock brake sensor. Installation 1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 7600 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7611 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7612 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7613 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7614 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7615 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7618 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7619 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7620 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 7624 Neutral Safety Switch: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7632 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7633 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7634 Starter Relay: Service Precautions WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7635 Starter Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7636 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. 1. Disconnect the battery ground cable. 2. Disconnect the starter motor solenoid relay switch wiring. 1 Remove the protective cover. 2 Disconnect the push-on electrical connector. 3 Remove the nuts. 4 Remove the cable. 3. Remove the starter motor solenoid relay switch. 1 Remove the engine sensor/generator wires. 2 Remove the bolts and ground wire. 3 Remove the starter motor solenoid relay switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Battery Cable Clamp Bolts 7-10 Nm Battery Cable Bolts 7-10 Nm Battery Ground Cable To Engine Block Stud Nut 11-20 Nm Battery Ground Cable To Frame Bolt 11-13 Nm Battery Ground Cable To Radiator Support Nut 11-13 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 7641 Battery Cable: Service and Repair REMOVAL 1. Disconnect the battery cables. 1 Disconnect the battery ground cable. 2 Disconnect the battery to starter relay cable. 2. Remove the battery cable to battery tray pushpins. 3. Remove the starter motor solenoid top nut insulator. 4. Remove the two starter motor solenoid relay switch cable nuts and the starter motor solenoid relay switch cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 7642 5. Remove the nut and the chassis ground cable. 6. Raise and support the vehicle; refer to Maintenance/Service and Repair. 7. Remove the screw and the frame ground cable. 8. Remove the nut and the battery cable bracket. 9. Remove the battery ground cable from the engine block stud. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 7643 10. Remove the nut and the battery cable bracket. 11. Remove the nut and the battery cable bracket. 12. Remove the starter motor wiring harness. 1 Remove the push-on electrical connector. 2 Remove the starter motor wiring harness to starter motor nut and wire. ^ Remove battery cable wiring harness. INSTALLATION 1. Install the starter motor wiring harness. 1 Install the starter motor wiring harness to starter motor wire and nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 7644 2 Install the push-on electrical connector. 2. Install the battery cable bracket and the nut. 3. Install the battery cable bracket and the nut. 4. Install the battery ground cable on the engine block stud. 5. Install the battery cable bracket and the nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 7645 6. Position the frame ground cable and install the bolt. 7. Lower the vehicle. 8. Install the chassis ground cable and the nut. 9. Install the starter motor solenoid relay switch cable and the two starter motor solenoid relay switch cable nuts. 10. Install the starter motor solenoid top nut insulator. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 7646 11. Install the positive battery cable to battery tray pushpin. 12. Install the battery ground cable to battery tray pushpin. 13. Connect the battery to starter relay cable and then connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Alternator Pulley > Component Information > Service and Repair Alternator Pulley: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery Service and Repair. 2. Remove the Generator (GEN). For additional information, refer to Generator Service and Repair. 3. Remove the (A) nut and the (B) generator pulley. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Voltage Regulator/Brush Holder Screws 2.3-3.4 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 7658 Voltage Regulator: Service and Repair REMOVAL 1. Remove the generator. For additional information, refer to Generator Service and Repair. 2. Remove the voltage regulator/brush holder assembly. 1 Remove the screws. 2 Remove the voltage regulator/brush holder assembly. INSTALLATION 1. Install the voltage regulator/brush holder assembly. 1 Depress the brushes and insert a wire to hold brushes during installation. 2 Install the voltage regulator/brush holder assembly. 3 Install the screws and remove the wire. 2. Install the generator. For additional information, refer to Generator Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7668 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7669 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7670 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7671 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7672 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7675 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7676 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7677 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 7681 Neutral Safety Switch: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Locations > Page 7686 Starter Drive/Bendix: Testing and Inspection STARTER DRIVE AND FLYWHEEL RING GEAR INSPECTION 1. Remove the starter motor; refer to Starter Motor Service and Repair. 2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern is normal, install the starter motor; refer to Starter Motor Service and Repair. 3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are scored or damaged, replace the starter motor; refer to Starter Motor Service and Repair. If necessary, replace the flywheel; refer to Engine. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7690 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7691 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7692 Starter Relay: Service Precautions WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7693 Starter Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7694 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. 1. Disconnect the battery ground cable. 2. Disconnect the starter motor solenoid relay switch wiring. 1 Remove the protective cover. 2 Disconnect the push-on electrical connector. 3 Remove the nuts. 4 Remove the cable. 3. Remove the starter motor solenoid relay switch. 1 Remove the engine sensor/generator wires. 2 Remove the bolts and ground wire. 3 Remove the starter motor solenoid relay switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Solenoid Bolts 5-10 Nm Starter Solenoid B-Terminal Nut 10-15 Nm Starter Solenoid S-Terminal Nut 5-7 Nm B+ Terminal Nut 9-12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 7698 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7707 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7708 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7709 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7710 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7714 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7715 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7716 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7717 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7718 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7719 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7720 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7721 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7722 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7723 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7724 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7735 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7736 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7737 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7738 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7739 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7740 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7741 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7742 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7748 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7749 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7750 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7751 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7752 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7753 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7754 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7755 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7760 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7761 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7762 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7763 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7764 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7765 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7766 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7767 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7768 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7769 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7770 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7771 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7790 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7791 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7792 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7793 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7794 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7795 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7796 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7797 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7798 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7799 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7800 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7801 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7806 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7807 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7808 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7809 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7810 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7811 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7812 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7813 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7814 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7815 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7816 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7817 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7820 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7821 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7822 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7823 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7824 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7825 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7826 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7827 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7828 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7829 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7830 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7831 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7832 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7833 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7836 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7837 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7838 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7839 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7840 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7841 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7842 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7843 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7844 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7845 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Specifications Ground Strap: Specifications Intake Manifold Ground Strap Nut ...................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Battery Ground Cable Screw .............................................................................................................................................................. 7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt .............................................................................................................................................. 8.9-12.1 Nm (79-107 Lb-In) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 7849 Ground Strap: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and washer (A) attaching the ground strap (B) to the stud. 3. Remove the fastener from the rear of the intake manifold and ensure that the mounting surfaces of the studs are free of dirt and corrosion. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 7850 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7861 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7862 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7863 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7864 Multiple Junction Connector: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7865 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7866 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7867 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7868 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7869 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7870 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7871 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7872 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7873 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7874 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7875 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7876 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7877 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7878 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7879 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7880 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7881 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7882 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7883 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7884 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7885 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7886 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7887 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7888 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7889 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7890 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7891 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7892 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7893 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7894 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7895 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7896 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7900 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7901 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7902 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7913 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7914 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7915 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7920 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7921 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7922 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7923 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7924 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7925 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7926 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7927 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7928 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7929 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7930 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7931 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7934 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7935 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7936 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7937 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7940 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7941 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7942 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7943 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7944 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7945 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7946 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7947 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7948 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7949 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7950 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7951 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7956 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7957 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7958 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7959 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7960 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7961 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7962 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7963 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7964 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7965 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7966 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7967 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7970 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7971 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7972 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7973 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7976 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7977 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7978 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7979 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7980 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7981 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7982 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7983 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7984 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7985 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7986 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7987 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7992 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7993 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7994 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7995 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7996 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7997 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7998 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7999 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8000 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 8009 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 8010 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 8011 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 8012 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8015 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8016 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8017 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8018 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8019 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8024 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8037 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8038 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8039 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8040 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8041 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8042 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8043 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8044 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8050 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8051 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8052 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8053 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8054 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8055 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8056 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8057 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8062 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8063 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8064 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8065 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8066 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8067 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8068 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8069 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8070 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8071 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8072 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8073 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8092 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8093 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8094 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8095 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8096 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8097 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8098 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8099 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8100 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8101 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8102 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8103 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8108 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8109 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8110 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8111 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8112 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8113 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8114 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8115 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8116 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8117 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8118 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8119 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8138 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8139 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8140 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8141 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8142 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8143 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8144 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8145 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8146 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8147 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications Ground Strap: Specifications Intake Manifold Ground Strap Nut ...................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Battery Ground Cable Screw .............................................................................................................................................................. 7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt .............................................................................................................................................. 8.9-12.1 Nm (79-107 Lb-In) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 8151 Ground Strap: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and washer (A) attaching the ground strap (B) to the stud. 3. Remove the fastener from the rear of the intake manifold and ensure that the mounting surfaces of the studs are free of dirt and corrosion. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 8152 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8163 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8164 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8165 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8166 Multiple Junction Connector: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8167 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8168 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8169 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8170 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8171 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8172 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8173 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8174 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8175 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8176 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8177 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8178 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8179 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8180 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8181 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8182 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8183 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8184 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8185 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8186 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8187 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8188 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8189 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8190 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8191 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8192 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8193 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8194 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8195 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8196 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8197 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 8198 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 8202 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 8203 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 8204 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 8215 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 8216 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 8217 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8222 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8223 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8224 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8225 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8226 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8227 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8228 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8229 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8230 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8231 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8232 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8233 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8236 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8237 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8238 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8239 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8242 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8243 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8244 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8245 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8246 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8247 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8248 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8249 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8250 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8251 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8252 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8253 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8258 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8259 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8260 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8261 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8262 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8263 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8264 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8265 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8266 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8267 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8268 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8269 Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8272 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8273 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8274 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 8275 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8278 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Central Junction Box Fuse 1 - 18 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8279 Central Junction Box Fuse 19 - 36 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8280 Fuse 1 - 15 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8281 Fuse 16 - 33 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8282 Fuse 34 - 36 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8283 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Power Distribution Box Location Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8284 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8285 Battery Junction Box Fuses Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8286 Battery Junction Box Relays Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8287 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8288 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8289 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8294 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8295 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8296 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8297 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8298 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8299 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8300 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8301 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8302 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 8308 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 8309 Alignment: Specifications Caster LH 4.2 - 1.0 deg 0 deg. Frame Angle (If vehicle is higher in the rear, add the frame angle to the measured caster. If vehicle is lower in the rear, subtract the frame angle from the measured caster. Compare the total to the specification.) RH 4.2 - 1.0 deg Total/Split -0.7 +/- 0.5 deg Camber LH -0.5 +/- 0.5 deg RH -0.5 +/- 0.5 deg Total/Split 0 +/- 0.7 deg Toe 0.12 +/- 0.25 deg @ Curb Ride Height (positive value is toe-in, negative value is toe-out) Wheel Track 0.02 in Dogtracking 1.18 in maximum (centerline of front tires compared to centerline of rear tires) Clear Vision -2.4 +/- 3.0 deg (negative value is counterclockwise) Front Ride Height New Vehicles With less than 500 miles 4.4 +/- 0.4 in Original Parts 4.0 +/- 0.4 in Replacement Parts 4.4 +/- 0.1 in Rear Ride Height 4 Door Vehicles 5 - 5.8 in 2 Door Vehicles 4.3 - 4.8 in Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in Upper Ball Joint Maximum 1/32 in Vehicle Lean Front Wheel Opening Maximum 0.6 in Side to Side Height Differences Rear Wheel Opening Maximum 0.78 in Torque Specifications Caster Set Jam Nuts 129 ft lb Front Suspension Upper Arm Cam Nuts 98 ft lb Toe Set Jam Nuts 59 ft lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 8312 Alignment: Description and Operation Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 8313 Alignment: Description and Operation Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 8314 Alignment: Description and Operation Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 8315 Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Dogtracking Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 8316 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). General Information Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Ride Height Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 8317 Front Ride Height Measurement Rear Ride Height Measurement Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Toe Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 8318 Positive Toe (Toe In) Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the farm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 4. To decrease the LF caster and camber, use the following steps. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 8321 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 8322 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 8323 Alignment: Service and Repair Ride Height Ride Height - Front Suspension 1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to normalize the vehicle static ride height. 3. Measure the distance between the center line of the front suspension lower arm bushing bolt and the lift. Record the measurement. 4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the measurement. 5. Determine ride height. ^ Subtract measurement 1 from measurement 2. This is the ride height. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 8324 6. Note: The torsion bar adjusting bolt is coated with adhesive that wears; off after disassembly. If the torsion bar system is ever disassembled or the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when re-assembling. Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting bolt. ^ Tighten the torsion bar adjusting bolt to increase the torque or raise the height. ^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height. Ride Height - Vehicle Dynamic Suspension Special Service Tool(s) 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid). ^ VENT (vent solenoid). 3. Close all doors including the liftgate and liftgate window. 4. Reopen any door (to ensure that the height will not change until the internal electronic calibration is complete). 5. Park the vehicle on a flat surface. 6. From the function menu, quickly select RIDE HEIGHT CALIBRATION. 7. Note the warning on the scan tool screen and follow the directions. 8. Lower the vehicle and clear all stored Diagnostic Trouble Codes (DTCs). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 8325 Alignment: Service and Repair Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. Note: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod (3280) is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 8326 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8332 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8336 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8337 Suspension Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8338 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8339 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 8346 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Special Service Tool(s) Removal 1. Remove the wheel hub. 2. Remove the torsion bar cover plate. 1 Remove the retaining bolts. 2 Remove the torsion bar cover plate. 3. Note: Before relieving the torsion bar tensions, measure and record the measurement of the torsion bar adjustment bolt. This measurement will be used as the preset depth for the new torsion bar adjustment bolt during installation. Measure and record the length where indicated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 8354 4. Relieve the torsion bar tension. 1 Position the torsion bar tool and the adapters. 2 Tighten the torsion bar tool until the torsion bar adjuster lifts off of the adjustment bolt. 5. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Remove the torsion, bar adjustment bolt and nut. 6. Loosen the torsion bar adjustment tool until the tension is off the torsion bar. 7. Reposition the anti-lock sensor wire. 1 Remove the front brake anti-lock sensor wire bracket bolt. 2 Reposition the anti-lock sensor wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 8355 8. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can cause damage to the front axle shaft. Suspend the front axle shaft with wire. 9. Remove the tie rod end castellated nut. 1 Remove the tie rod end cotter pin. 2 Remove the tie rod end castellated nut. 10. Use the Pitman Arm Puller to separate the tie rod end. ^ Separate the tie rod end from the front wheel knuckle. 11. Remove the lower ball joint castellated nut. 1 Remove the lower ball joint cotter pin. 2 Remove the lower ball joint castellated nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 8356 12. Use the Pitman Arm Puller to separate the front wheel knuckle front the front suspension lower arm. 13. Remove the pinch bolt. 14. Remove the front wheel knuckle. Installation 1. Install the front wheel knuckle pinch bolt and nut. 1 Position the front wheel knuckle on the front suspension upper arm. 2 Install the pinch bolt and nut. 2. Install the front suspension arm lower ball joint castellated nut. 1 Position the front wheel knuckle, 2 Install the castellated nut. 3 Install a new cotter pin. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 8357 3. Install the tie rod end castellated nut. 1 Position the tie rod end. 2 Install the tie rod end castellated nut. 3 Install a new cotter pin. 4. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Preload the torsion bar. 1 Tighten the torsion bar tool until the new adjustment bolt and nut can be installed. 2 Turn the adjustment bolt until preliminary adjustment marks are aligned. 5. Remove the torsion bar tool and adapters. 6. Install the torsion bar cover plate. 1 Position the torsion bar cover plate. 2 Install the retaining bolts. 7. Install the wheel hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 8358 8. Install the anti-lock sensor wire bracket bolt. 1 Position the anti-lock sensor wire. 2 Install the bolt. 9. Adjust the ride height. 10. Check the alignment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Special Tools Special Service Tool(s) CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure could result. The condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. Note: A whine heard from the power steering pump may be caused by air in the system. The power steering purge procedure must be performed prior to any component repair for which power steering noise complaints arc accompanied by evidence of aerated fluid. Remove the reservoir cap. Check the fluid. ^ Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or MERCON equivalent. 2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle. 4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at idle. 5. Release the vacuum and remove the vacuum pump. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 8363 6. CAUTION: Do not overfill the power steeling pump reservoir. Fill the reservoir. ^ Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or MERCON equivalent. 7. Reinstall the vacuum pump. Apply and maintain maximum vacuum. 8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump could occur. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum, and remove the vacuum pump. 10. Install the reservoir cap. 11. Check fir fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 8368 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 8369 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Fluid Cooler Nuts 59 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 8373 Power Steering Fluid Cooler: Service and Repair Removal 1. Disconnect the power steering return line hose at the power steering fluid cooler. ^ Allow the system to drain. 2. Remove the power steering fluid cooler to crossmember nuts. 3. Disconnect the power steering return hose. Remove the power steering fluid cooler. Installation 1. Follow the removal procedure in reverse order. 2. Fill, and leak check the system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose to Power Steering Pump 48 ft.lb Power Steering Pump Bolts 18 ft.lb Steering Gear Pressure Fittings 22 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 8377 Power Steering Line/Hose: Service and Repair Special Tools Special Service Tool(s) Removal 1. Refer to the Description and Operation for the hose routing and retention points. Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Pump Pulley Bolts 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 8382 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow Rate 2.1 - 2.5 gal/min Flow Rate @ 74 - 80 degrees C (165 - 175 degrees F) and Engine Speed Set at 1500 RPM Maximum Pressure 150 psi Maximum Pressure @ 74 - 80 deg C (165 - 175 deg F) and Engine Speed Set at 1500 RPM Minimum Flow Rate 0.95 gal/min Minimum Flow Rate @ 74 - 80 deg C (165 - 175 deg F), Power Steering Analyzer Set at 5,102 kPa (750 psi) and Engine Speed Set at Idle Relief Pressure 1300 - 1480 psi Flow Rate 2.2 - 2.6 gal/min Flow Rate @ 74 - 80 degrees C (165 - 175 degrees F) and Engine Speed Set at 1500 RPM Maximum Pressure 150 psi Maximum Pressure @ 74 - 80 deg C (165 - 175 deg F) and Engine Speed Set at 1500 RPM Minimum Flow Rate 1.15 gal/min Minimum Flow Rate @ 74 - 80 deg C (165 - 175 deg F), Power Steering Analyzer Set at 5,102 kPa (750 psi) and Engine Speed Set at Idle Relief Pressure 1300 - 1480 psi Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 8383 Power Steering Pump Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Special Tools Special Service Tool(s) Removal 1. Remove the drive belt. 2. Disconnect the power steering return line hose at the power steering fluid cooler. ^ Drain the power steering oil reservoir. 3. Disconnect the power steering pressure hose from the power steering pump. 4. Disconnect the power steering oil reservoir outlet hose from the power steering pump. 1 Compress and move the power steering oil reservoir outlet hose clamp. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8386 2 Disconnect the power steering oil reservoir outlet hose from the power steering pump. 5. Remove the rear bolt. 6. Remove the power steering pump. 1 Remove the three front bolts. ^ Rotate the pulley to access each bolt. 2 Remove the power steering pump. Installation 1. Install the power steering pump. 1 Position the power steering pump. 2 Install the three front bolts. ^ Rotate the pulley to access each bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8387 2. Install the rear bolt. 3. Connect the power steering oil reservoir outlet hose to the power steering pump. 1 Connect the power steering oil reservoir outlet hose to the power steering pump. 2 Compress and move the power steering oil reservoir outlet hose clamp. 4. Using the special tool, install a new seal on the power steering pressure hose. 5. Connect the power steering pressure hose to the power steering pump. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8388 6. Connect the power steering return line hose to the power steering fluid cooler. 7. Install the drive belt. 8. Fill, and leak check the system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8389 Power Steering Pump: Service and Repair Power Steering Pump Pulley Removal 1. Remove the engine cooling fan. 2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt. 4. Remove the power steering pump pulley. 1 Remove the bolts. 2 Remove the power steering pump pulley. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8395 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8396 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8397 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8398 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8399 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8400 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder Steering Column Lock: Service and Repair Ignition Switch Lock Cylinder Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8408 WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8409 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8410 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8411 Steering Column Lock: Service and Repair Key Release Button Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8412 2 Remove the upper and lower steering column shrouds. 5. Remove the key release lever. 1 Remove the key release lever bolt. 2 Remove the release lever handle and the spring. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Type Rack and Pinion Steering Gear Turns (Stop to Stop) 3.2/4.0 To Crossmember Stud Bolts and Nuts 111 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8416 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8417 Steering Gear: Testing and Inspection 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. Rotate the steering wheel to the RH stop, then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. 4. Turn the steering wheel another 90° Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50 200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard, or a strong shudder is felt, fill and purge the power steering system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8418 Steering Gear: Service and Repair Removal 1. Place the front wheels in the straight ahead position. Do not lock the steering column. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle. 3. Remove the engine oil cooler. 4. Remove the front wheel and tire assemblies. 5. Remove the inner fender splash shields. 6. Remove the top motor mount nuts. 7. Remove the bolts and the radiator air deflector. 8. Loosen the LH tie-rod end jam nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8419 9. Disconnect the tie-rod ends. 1 Remove and discard the cotter pins. 2 Remove the castellated nuts. 3 Separate the tie-rod ends from the steering knuckles. Do not damage the tie-rod end seals. 10. Remove the LH tie-rod end. ^ Count and record the number of turns required to remove the LH tie-rod end. 11. Remove the front stabilizer bar. ^ Mark the driver side end of the stabilizer bar for correct installation. 12. Remove the power steering fluid cooler to crossmember nuts. 13. Disconnect the power steering return line hose at the power steering fluid cooler. ^ Allow the system to drain. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8420 14. Disconnect the power steering return hose and remove the power steering fluid cooler. 15. Disconnect the steering gear lines. 1 Disconnect the power steering pressure hose. 2 Disconnect the power steering return hose. 16. Plug the ends of all fluid lines removed and ports in steering gear to prevent damage and entry of dirt. 17. Rotate the steering column shaft to access the Intermediate shaft pinch bolt. Remove the pinch bolt. 18. Lower the vehicle. 19. Turn the steering wheel back to the straight ahead position. Turn the ignition key to the locked position. 20. Raise the vehicle. 21. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected, or damage to the air bag sliding contact will result. Disconnect the intermediate shaft from the steering gear input shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8421 22. Raise the engine. ^ Position a block of wood between a screw jack and the bottom of the oil pan to avoid damaging the oil pan while raising the engine. 23. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Remove the nuts. 24. Remove the stud bolts and washers. 25. Remove the steering gear to crossmember insulator bushings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8422 26. Rotate the steering gear control valve housing toward the front of the vehicle. 27. Turn the steering gear input shaft to the right until the stop is reached. 28. Move the steering gear as far to the RH side of the vehicle as possible. 29. Move the LH front wheel spindle tie-rod forward to clear the crossmember. Turn the steering gear input shaft to the left until the stop is reached. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8423 30. Remove the steering gear from the vehicle. Installation 1. Using the special tool, install new seals on the power steering return hose and power steering pressure hose. 2. Note: Make sure the steering gear input shaft is turned to the left until the stop is reached. Note: Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in the tie-rod boots. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required. 3. Note: Make sure the steering gear control valve housing is turned toward the front of the vehicle. Install the steering gear into the RH opening of the crossmember. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8424 4. Move the steering gear as far to the RH side of the vehicle as possible. 5. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position. 6. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously. 7. Rotate the steering gear control valve housing toward the rear of the vehicle. 8. Install the steering gear to crossmember insulator bushings as shown. ^ The large end of metal sleeve must be positioned downward. ^ Check that the mounting surfaces on the crossmember are clean and free of debris. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8425 9. Install the steering gear to crossmember washers and stud bolts. 10. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Install the nuts. 11. Lower the engine. 12. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected, or damage to the air bag sliding contact will result. Connect the intermediate shaft to the steering gear input shaft. Install the pinch bolt. 13. Connect the steering gear fluid lines. 1 Connect the power steering return hose. 2 Connect the power steering pressure hose. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8426 14. Connect the power steering return hose to the power steering fluid cooler. 15. Position the power steering fluid cooler and install the power steering fluid cooler to crossmember nuts. 16. Connect the power steering return line hose to the power steering fluid cooler. 17. Install the engine oil cooler. 18. Install the front stabilizer bar. ^ Orientate the front stabilizer bar as noted during removal. 19. Install the tie-rod end. ^ Rotate the tie-rod end the number of turns recorded during removal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8427 20. Connect the tie-rod ends to the steering knuckles. 1 Position the tie-rod ends to the steering knuckles. 2 Install the castellated nuts. 3 Install the new cotter pins. ^ Check that brake dust shields are not bent and are not in contact with the outer tie-rod boot seals. 21. Tighten the LH tie-rod end jam nut. 22. Install the radiator air deflector. 23. Install the top engine mount nuts. 24. Install the inner fender splash shields. 25. Install the front wheel and tire assemblies. 26. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8428 27. Refill and bleed the engine cooling system. 28. Fill and leak check the power steering system. 29. Check the wheel alignment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Lower Intermediate Shaft Pinch Bolt 36 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 8440 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 8446 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8447 Steering Wheel: Specifications Steering Wheel Bolt 25 - 34 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8448 Steering Wheel: Service and Repair Special Tool(s) Special Service Tool(s) Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Note: Make sure the wheels are in the straight-ahead position. 1. Disconnect the battery cable and wait at least one minute. ^ Disconnect the battery ground cable. ^ Disconnect the battery to starter relay cable. 2. Remove the driver air bag module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8449 3. Remove the steering wheel bolt. 4. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the 2-Jaw Puller to remove the steering wheel. 5. Remove and discard the original steering wheel bolt. 6. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8450 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Follow the removal procedure in reverse order. 2. Connect the battery cables. 3. Prove out the air bag system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod End Nut 44 - 59 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8460 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8461 Ball Joint: Specifications Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8462 Ball Joint: Specifications Ball Joint Radial Play Upper Ball Joint Maximum 1/32 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8465 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8466 Ball Joint: Testing and Inspection Ball Joint, Lower 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Install a new ball joint as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front suspension upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball joint as necessary. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8467 Ball Joint: Testing and Inspection Ball Joint, Upper 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Install a new ball joint as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front suspension upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball joint as necessary. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8468 Ball Joint: Service and Repair Special Tool(s) Special Tool(s) Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel and tire assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8469 3. CAUTION: Do not reuse the torque prevailing design hub nut and washer assembly. Remove and discard the hub nut and washer assembly. 4. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper and support bracket aside. 5. Remove the brake disc. 6. CAUTION: Do not use a hammer to separate the outboard front wheel halfshaft joint from the wheel hub. Damage to the outboard CV joint stub shaft threads and internal CV joint components may result. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8470 Using the special tool, separate the outboard front wheel halfshaft joint from the wheel hub. Remove the special tool. 7. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame. 1. Disconnect the ABS electrical connector. 2. Unclip the front ABS wire from the vehicle frame. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8471 8. Using a suitable jack, support the front suspension lower arm. 9. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can cause damage to the front axle shaft. Support the front axle shaft with wire. 10. Remove the tie-rod end castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 11. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8472 Using the special tool, separate the tie-rod end from the front wheel knuckle. 12. Remove the lower ball joint castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8473 13. Using the special tool, separate the front wheel knuckle from the front suspension lower arm then, loosely install the lower ball joint castellated nut. 14. Remove the pinch bolt and nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8474 15. Remove the hand-tightened lower ball joint castellated nut, then remove the front wheel knuckle. 16. Remove the snap ring from the ball joint. Discard the snap ring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 8475 17. Using a suitable ball joint remover tool, remove the ball joint. 18. CAUTION: Do not damage the ball joint boot when installing the special tool. NOTE: Clean and inspect the control arm ball joint bore for damage before installing a new ball joint. NOTE: Make sure the new ball joint snap ring is fully seated. To install, reverse the removal procedure. Always install new castellated nuts and cotter pins. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair Removal and Installation NOTE: The control arm bushings are not serviced separately. If the bushings require service, the front suspension lower arm or the front suspension upper arm will have to be installed new. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Special Service Tool(s) Removal 1. Remove the wheel hub. 2. Remove the torsion bar cover plate. 1 Remove the retaining bolts. 2 Remove the torsion bar cover plate. 3. Note: Before relieving the torsion bar tensions, measure and record the measurement of the torsion bar adjustment bolt. This measurement will be used as the preset depth for the new torsion bar adjustment bolt during installation. Measure and record the length where indicated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 8483 4. Relieve the torsion bar tension. 1 Position the torsion bar tool and the adapters. 2 Tighten the torsion bar tool until the torsion bar adjuster lifts off of the adjustment bolt. 5. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Remove the torsion, bar adjustment bolt and nut. 6. Loosen the torsion bar adjustment tool until the tension is off the torsion bar. 7. Reposition the anti-lock sensor wire. 1 Remove the front brake anti-lock sensor wire bracket bolt. 2 Reposition the anti-lock sensor wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 8484 8. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can cause damage to the front axle shaft. Suspend the front axle shaft with wire. 9. Remove the tie rod end castellated nut. 1 Remove the tie rod end cotter pin. 2 Remove the tie rod end castellated nut. 10. Use the Pitman Arm Puller to separate the tie rod end. ^ Separate the tie rod end from the front wheel knuckle. 11. Remove the lower ball joint castellated nut. 1 Remove the lower ball joint cotter pin. 2 Remove the lower ball joint castellated nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 8485 12. Use the Pitman Arm Puller to separate the front wheel knuckle front the front suspension lower arm. 13. Remove the pinch bolt. 14. Remove the front wheel knuckle. Installation 1. Install the front wheel knuckle pinch bolt and nut. 1 Position the front wheel knuckle on the front suspension upper arm. 2 Install the pinch bolt and nut. 2. Install the front suspension arm lower ball joint castellated nut. 1 Position the front wheel knuckle, 2 Install the castellated nut. 3 Install a new cotter pin. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 8486 3. Install the tie rod end castellated nut. 1 Position the tie rod end. 2 Install the tie rod end castellated nut. 3 Install a new cotter pin. 4. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Preload the torsion bar. 1 Tighten the torsion bar tool until the new adjustment bolt and nut can be installed. 2 Turn the adjustment bolt until preliminary adjustment marks are aligned. 5. Remove the torsion bar tool and adapters. 6. Install the torsion bar cover plate. 1 Position the torsion bar cover plate. 2 Install the retaining bolts. 7. Install the wheel hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 8487 8. Install the anti-lock sensor wire bracket bolt. 1 Position the anti-lock sensor wire. 2 Install the bolt. 9. Adjust the ride height. 10. Check the alignment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8492 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8496 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8497 Suspension Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8498 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8499 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 8505 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications Spindle: Specifications To Lower Ball Joint Nut 83 - 113 ft.lb To Upper Ball Joint Nut 35 - 46 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Front Stabilizer Bar Link Nuts 15 - 21 ft.lb Rear Stabilizer Bar to Link Nut 50 - 68 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Service and Repair Air Dryer: Service and Repair Removal 1. Remove the air compressor. 2. Remove the air compressor drier. 1 Remove the screw. 2 Rotate 90° to unlock then remove the air compressor drier. Installation 1. Note: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Note: Ride height adjustments must be performed after the air compressor/drier is installed. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge Air Line: Service and Repair Air Line Fluid Purge Note: Perform this procedure if fluid (water or oil) is found in the rear air lines. Purge fluid from air lines and replace affected components. 1. Disconnect air line at compressor air drier that is connected to front fill solenoid inlet. 2. Disconnect air line at inlet of front fill solenoid. 3. Connect stop air line to disconnected air line and blow out any water 4. Reconnect air line. 5. Disconnect air line at compressor air drier that is connected to the rear fill solenoid inlet. 6. Disconnect air line at RR shock absorber. 7. Connect scan tool to Data Link Connector (DLC). 8. Using the RIDE CONTROL OUTPUT command, turn on the following actuators: ^ REAR_FIL (rear fill solenoid) ON. 9. Connect shop air line to disconnected air line and blow out any water. 10. Reconnect air line at RR shock absorber. 11. Disconnect air line at LR shock absorber. 12. Using the RIDE CONTROL OUTPUT command, turn on the following actuators: ^ REAR_FIL(rearfill solenoid) ON. ^ GATE VALVE (front and rear gate solenoids) ON. 13. Connect shop air line to disconnected air line and blow out any water. 14. If oil was present in air lines, replace BOTH LR and RR shock absorbers. (Do not replace s hock absorbers if only water is in the lines.) 15. Replace compressor air drier. 16. Reconnect air line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge > Page 8524 Air Line: Service and Repair Air Line Repair Note: A soapy water solution can be applied to the air lines to verify the location of air leaks. 1. If a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight cut. Trim back the outer covering of the air line 16 - 20 mm (0.63 - 0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely with electrical tape. 2. If multiple leaks are detected, replace the entire air line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications Compressor/Pump: Specifications Air Compressor Assembly to Frame Mounting Bolts 13 - 17 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 8528 Compressor/Pump: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire. 3. Disconnect the air compressor electrical connector. 4. Disconnect the air line from the drier. 1 Compress the quick connect locking ring and pull out the air line. 2 Remove the air line from the drier. 5. Remove the air compressor assembly from the vehicle. 1 Remove the air compressor bolts. 2 Remove the air compressor assembly. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 8529 1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8533 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill Level Control Solenoid Valve: Service and Repair Solenoid Valve-Rear Fill Special Service Tool(s) Removal 1. Connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid[s]). ^ VENT (vent solenoid). 3. Raise and support the vehicle. 4. Remove the spare tire. 5. Remove the solenoid valve from the frame. 6. Compress the quick connect locking ring and pull out the air line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 8538 7. Disconnect the solenoid valve electrical connector. Installation 1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 8539 Level Control Solenoid Valve: Service and Repair Solenoid Valve-Rear Gate Special Service Tool(s) Removal 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid[s]). ^ VENT (vent solenoid). 3. Raise and support the vehicle. 4. Remove the spare tire. 5. Remove the evaporative canister. 6. Remove the solenoid valve from the frame. 7. Compress the quick connect locking ring and pull out the air line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 8540 8. Disconnect the solenoid valve electrical connector. Installation 1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 8545 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 8549 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 8550 Suspension Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 8551 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 8552 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Rear Spring Shackle Lower Bolt and Nut 85 ft.lb Rear Spring to Front Frame Bracket Bolt and Nut 66 ft.lb Rear Spring U-bolt Nut 76 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8559 Suspension Spring ( Coil / Leaf ): Service and Repair Spring Tools Special Service Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Use the Hi-Lift Jack to support the rear axle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8560 5. Separate the rear spring from the rear axle. 1 Remove the four nuts. 2 Remove the two U-bolts. 3 Position the rear spring plate aside. 6. Remove the rear spring. 1 Remove the bolt and nut. 2 Remove the bolt and nut. 3 Remove the roar spring. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Front To Lower Arm Nuts 15 - 21 ft.lb To Frame Mounting Nut 30 - 41 ft.lb Rear Shock Absorber to Frame Nuts 17 ft.lb Shock Absorber Lower Bolt 46 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 8564 Suspension Strut / Shock Absorber: Service and Repair Special Service Tool(s) Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: The low pressure gas shock absorbers are charged with nitrogen gas 930 kPa (135 psi). Do not attempt to open, puncture, or apply heat to the shock absorbers. 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATEVALVE(gate solenoid[s]). ^ VENT (vent solenoid). 3. Raise and support the vehicle. 4. Remove the spare tire. 5. Use Hi-Lift Transmission Jack to support the rear axle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 8565 6. Remove the rear shock absorber electrical connector from the rear crossmember and disconnect the electrical connector. 7. Disconnect the air line from the shock absorber. ^ Compress the quick connect locking ring and pull out the air line. 8. Remove the shock absorber lower retaining nut and bolt and swing the shock absorber out of the lower mounting bracket. 9. Remove the attaching nuts on top of the rear crossmember and remove the shock absorber. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 8566 1. Note: When installing air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Front Jounce Bumper to Frame Nut 18 - 26 ft.lb Rear Jounce Bumper Nut 15 - 21 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications Cover Plate Bolts 35 - 46 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8573 Torsion Bar: Service and Repair Special Service Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs or shocks, which can result in shifting of the vehicle during these operations. Raise the vehicle on a hoist. 2. Remove the torsion bar cover plate. 1 Remove the torsion bar cover plate bolts. 2 Remove the torsion bar cover plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8574 3. Note: Before relieving the torsion bar tension, measure and record the measurement of the torsion bar adjustment bolt. This measurement will be used as the preset depth for the new torsion bar adjustment bolt during installation. Make preliminary adjustment. ^ Measure and record the length where indicated. 4. Relieve the torsion bar tension. 1 Position the Torsion Bar Tool and adapters. 2 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off the adjustment bolt. 5. CAUTION: The torsion bar adjustment bolt is coated with: dry adhesive; and must be replaced if it is backed offer removed. Failure to do so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment. Remove the torsion bar adjustment bolt and nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8575 6. Loosen the Torsion Bar Tool until the tension is removed from the torsion bar. 7. Remove the torsion bar. 1 Mark the torsion bar and the adjuster for proper installation. 2 Remove the torsion bar insulator. 3 Grasp the torsion bar, and pull it free from the front suspension lower arm. Installation 1. Position the torsion bar and the torsion bar adjuster. 2. Install the torsion bar adjuster. 1 Align the marks on the torsion bar and the torsion bar adjuster, then install the torsion bar adjuster. 2 Position the torsion bar insulator. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8576 3. CAUTION: The torsion bar adjustment bolt is coated with: dry adhesive; and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment. Preload the torsion bar. 1 Install the Torsion Bar Tool and the adapters. 2 Tighten the Torsion Bar Tool until the new adjustment bolt and nut can be installed. 3 Turn the adjustment bolt until the preliminary adjustment measurement (recorded length of the old adjustment bolt) is reached. 4. Install the torsion bar cover plate. 1 Position the torsion bar cover plate. 2 Install the torsion bar cover plate bolts. 5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Adjust the ride height. 7. Check the alignment. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 8582 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 8583 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Special Service Tool(s) Removal 1. Remove the brake disc. 2. Remove the three bolts and the dust shield. 3. CAUTION: Discard the wheel hub retainer nut and washer assembly. It is a torque prevailing design and cannot be reused. Remove the wheel hub retainer nut and washer assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8586 4. Remove the front brake anti-lock sensor. 1 Remove the bolt. 2 Remove the front brake anti-lock sensor. 5. CAUTION: Do not overextend CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the three bolts and the wheel hub. 6. Remove the seal. Installation 1. Install the seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8587 ^ Using the Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer, install the seal. 2. Install the wheel hub. ^ Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. Install the three bolts. 3. Install the dust shield. 4. Install the front brake anti-lock sensor. 1 Position the front brake anti-lock sensor. 2 Install the bolt. 5. Install the wheel hub retainer nut and washer assembly. 6. Install the brake disc. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8588 Wheel Bearing: Service and Repair Rear Special Tools Special Tools Removal 1. Remove the axle shaft. See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8589 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Hub Nut 157-213 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear axle tube. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8598 Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8607 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8608 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8609 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8610 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8611 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8612 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8613 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8614 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8615 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8616 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8621 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8622 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8623 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8624 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8625 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8626 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8627 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8632 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8633 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8634 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8635 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8636 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8637 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8638 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8644 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8645 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8646 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8652 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8653 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8654 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8659 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8664 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8665 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8666 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8667 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8668 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8669 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8670 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8671 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8672 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8673 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8678 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8679 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8680 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8681 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8682 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8683 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8684 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8689 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8690 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8691 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8692 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8693 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8694 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8695 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8701 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8702 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8703 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8708 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8714 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8719 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8720 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8721 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8722 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8723 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8724 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8725 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8726 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8727 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8728 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8733 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8734 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8735 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8736 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8737 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8738 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8739 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8744 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8745 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8746 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8747 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8748 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8749 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 8750 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 8751 Tires: Specifications Tire Tread Depth P225/70R15 A/S 0.37 in P235/75R15 A/T 0.42 in P255/70R16 A/T 0.42 in Maximum Radial Runount Aluminum 0.040 in Steel 0.040 in Maximum Lateral Runout Aluminum 0.040 in Steel 0.040 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 8752 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 8753 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 8758 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8759 Wheels: Specifications Maximum Radial Runount Aluminum 0.045 in Steel 0.045 in Maximum Lateral Runout Aluminum 0.045 in Steel 0.045 in Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8760 Wheels: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 8763 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 8764 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 8770 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 8771 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Special Service Tool(s) Removal 1. Remove the brake disc. 2. Remove the three bolts and the dust shield. 3. CAUTION: Discard the wheel hub retainer nut and washer assembly. It is a torque prevailing design and cannot be reused. Remove the wheel hub retainer nut and washer assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8774 4. Remove the front brake anti-lock sensor. 1 Remove the bolt. 2 Remove the front brake anti-lock sensor. 5. CAUTION: Do not overextend CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the three bolts and the wheel hub. 6. Remove the seal. Installation 1. Install the seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8775 ^ Using the Knuckle Seal Replacer, Threaded Drawbar and Bearing Cup Replacer, install the seal. 2. Install the wheel hub. ^ Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. Install the three bolts. 3. Install the dust shield. 4. Install the front brake anti-lock sensor. 1 Position the front brake anti-lock sensor. 2 Install the bolt. 5. Install the wheel hub retainer nut and washer assembly. 6. Install the brake disc. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8776 Wheel Bearing: Service and Repair Rear Special Tools Special Tools Removal 1. Remove the axle shaft. See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8777 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Hub Nut 157-213 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts 100 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the brake disc and hub. 4. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 8787 Wheel Fastener: Service and Repair Rear Special Tool(s) Special Service Tool(s) Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which can result in shifting of the vehicle curing these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support the rear disc brake caliper with safety wire. 5. Using the C-Frame and Clamp Assembly Tool, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 8788 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. 2. Seat new wheel studs in axle flange. - Place four flat washers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flat washers. 4. Install the brake disc, rear disc support bracket the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Turn the air suspension service switch on, if so equipped. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Accumulator To Evaporator Core Fitting 35-42 Nm Suction/Accumulator Bracket Screws 6-8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8793 Accumulator HVAC: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8794 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8795 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8796 Accumulator HVAC: Service Precautions CAUTION: Use a back-up wrench to prevent damage to the tubes. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8797 Accumulator HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The suction accumulator/drier is mounted to the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube attaches to the A/C manifold and tube.After entering the inlet of the suction accumulator/drier, the heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8798 Accumulator HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 3. Disconnect the A/C cycling switch electrical connector. 4. Disconnect the suction accumulator/drier to A/C evaporator core fitting. CAUTION: Use a back-up wrench to prevent damage to the tubes. 5. Disconnect the A/C manifold and tube spring lock coupling from the suction accumulator/drier suction accumulator/drier. 6. Remove the suction accumulator/drier. 1 Remove the screw from the mounting bracket. 2 Lift the suction accumulator/drier out. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8799 7. Transfer the A/C cycling switch to the new suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. - Service the new suction accumulator/drier with the correct amount of PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. See: Refrigerant Oil Addition. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8800 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 8808 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > With Manual A/C W/O EATC Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > With Manual A/C > Page 8811 W/EATC Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 8812 Air Door Actuator / Motor: Service Precautions CAUTION: Do Not attempt to bend any part of the lever. It is brittle and will break. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 8813 Air Door Actuator / Motor: Description and Operation The A/C electric blend door actuator is located on the plenum assembly. - its function is to move the air temperature blend door on command from the control assembly. - The A/C electric blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. - A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the electronic automatic temperature control module and is matched with the wiper voltage of the module potentiometer. The control module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the control module wiper voltage. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Air Door Actuator / Motor: Service and Repair Blend Door REMOVAL 1. Release the stops and lower the glove compartment door to the floor. 2. Remove the screws and disconnect the vacuum hose. 3. Rotate the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door > Page 8816 Air Door Actuator / Motor: Service and Repair Blend Door Motor REMOVAL 1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair " See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the A/C electronic door actuator motor. - Remove the screws. - Disconnect the harness connector and remove the A/C electronic door actuator motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door > Page 8817 Air Door Actuator / Motor: Service and Repair Air Door Actuator / Motor, HVAC Air Inlet Duct Door Vacuum Control Motor REMOVAL 1. Release the stops and lower the glove compartment door to the floor. 2. Remove the screws and disconnect the vacuum hose. 3. Rotate the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Panel/Defrost Door Vacuum Control Motor REMOVAL Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door > Page 8818 1. Remove the screws and disconnect the vacuum hose. 2. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Panel/Floor Door Vacuum Control Motor REMOVAL 1. Remove the screws and disconnect the vacuum hose. 2. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor. CAUTION: Do Not attempt to bend any part of the lever. It is brittle and will break. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door > Page 8819 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Side Window Demister Hose And Nozzle Screws 2-3 Nm Windshield Defroster Hose Nozzle Screws 2-3 Nm Rear Floor Duct Screws 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 8823 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the console rear controls. 2. Remove the rear floor duct. 1. Remove the screws. 2. Remove the rear floor duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 8826 Air Duct: Service and Repair Windshield Defroster and Side Window Demister Nozzle REMOVAL 1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the two screws and remove the LH demister nozzle and duct. 3. Remove the two screws and remove the RH demister nozzle and duct. 4. Remove the screws and remove the windshield defroster hose nozzle. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 8827 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Specifications Air Register: Specifications LH Instrument Panel Register Screws 3.4-4.8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister Air Register: Service and Repair Defrost Nozzles and Side Demister REMOVAL 1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair " See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the two screws and remove the LH demister nozzle and duct. 3. Remove the two screws and remove the RH demister nozzle and duct. 4. Remove the screws and remove the windshield defroster hose nozzle. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8833 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8834 Air Register: Service and Repair Air Register Center Radio Removing Tool SPECIAL SERVICE TOOL(S) REMOVAL 1. Use the Radio Removing Tool to remove the radio chassis. 2. Disconnect the antenna lead and the wire harness connectors. 3. Remove the instrument panel finish panel. 1 Remove the screws. 2 Disengage the spring clips and remove the instrument panel finish panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8835 4. Disconnect the wire harness connector. 5. Release the eight clips and remove the center instrument panel register from the instrument panel finish panel. INSTALLATION 1. Follow the removal procedure in reverse order. Driver Side REMOVAL 1. Remove the LH instrument panel finish panel; refer to Dash Board. 2. Remove the LH instrument panel register. 1 Remove the screws. 2 Remove the LH instrument panel register. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 8836 INSTALLATION 1. Follow the removal procedure in reverse order. Passenger Side REMOVAL 1. Lift the edge of the RH instrument panel register to expose the retainers. 2. Release the retainers and remove the RH instrument panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 8837 Radio Removing Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8841 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 8850 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 00-3-6 > Feb > 00 > Customer Interest for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 00-3-6 > Feb > 00 > Customer Interest for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 8860 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > Page 8861 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 8870 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 8876 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 8877 Blower Motor: Locations Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 8878 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 8879 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8882 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8883 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8884 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8885 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8886 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8887 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8888 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8889 Blower Motor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8890 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8891 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8892 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8893 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8894 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8895 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8896 Blower Motor: Electrical Diagrams EATC This article has been updated by Technical Service Bulletin (TSB) 00-11-2 dated May 29, 2000 Although the electrical diagrams for the blower motor can be found at the system level, if your vehicle has a blower motor stuck on high speed, insufficient air across the in car temperature sensor may be the cause. Check for TSBs. For the wiring, refer to Heating and Air Conditioning / Diagrams. See: Diagrams/Electrical Diagrams MTC The diagrams for this component can be found at the system level. Refer to Heating and Air Conditioning / Diagrams. See: Diagrams/Electrical Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8897 Blower Motor: Description and Operation The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8898 Blower Motor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant/washer reservoir. 1 Remove the screws and the nuts. 2 Move the coolant/washer reservoir aside. 4. Remove the blower motor. 1 Disconnect the vent hose. 2 Disconnect the electrical connector. 3 Remove the four screws. 4 Remove the blower motor. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8899 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8904 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8905 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8906 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 8907 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 8908 Blower Motor Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8912 Component Locations The manual blower motor switch resistor and EATC blower motor speed control are located on the evaporator housing in the ENGINE COMPARTMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8913 Blower Motor Resistor: Description and Operation The heater blower motor switch resistor has the following features: - The assembly is located on the evaporator housing in the engine compartment. - Three resistance elements are mounted on the resistor board to provide four blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed. - An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F) interrupting the blower motor operation in all speeds except HIGH. - The thermal limiter cannot be reset and is not serviceable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8923 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the plenum assembly air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air Gap Between Pulley And Hub 0.35-0.85 mm A/C Clutch Bolt 11-14 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8928 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8929 Compressor Clutch: Description and Operation NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. Compressor Clutch Components The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. - The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch plate away from the A/C clutch pulley. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8930 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8931 Compressor Clutch: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8932 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Puller-Differential Side Bearing. 4 Remove the A/C clutch field coil. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8933 CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley bearing mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector properly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Replacer on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8934 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8935 Compressor Clutch Components 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8936 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions Compressor Shaft Seal: Service Precautions CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8943 Compressor Shaft Seal: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-Ring Removal Pick. 3. Clean the compressor nose area. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8944 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 7. Engage the Compressor Seal Remover into the inside diameter of the shaft seal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8945 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the seal protector. Lubricate the shaft seal and protector with PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. Position the shaft seal and the Seal Protector over the A/C compressor shaft. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8946 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Replacer until seated. 5. Install the shaft seal snap ring. 6. Conduct the A/C compressor external leak test. 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8947 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay Compressor Clutch Relay: Locations Compressor Clutch Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8952 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8953 Compressor Clutch Relay: Locations Compressor Cut-Off Relay Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8954 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8955 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications A/C Manifold Tube Bolt 17-23 Nm A/C Manifold To Generator Clamp Nut 15-22 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8959 Refrigeration System Components - 4.0L (5.0L Similar) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8960 Compressor Fitting HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8961 Special Tool(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Line To Condenser Nut 6.8-9.2 Nm A/C Condenser Core Bolt 8.4-11.2 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8965 Condenser HVAC: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8966 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8967 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8968 Condenser HVAC: Service Precautions CAUTION: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8969 Condenser HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8970 Condenser HVAC: Testing and Inspection On-Vehicle Leak Test 1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold (gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. if available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg)when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8971 Condenser HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8972 Special Tool(s) Set, A/C Fittings Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8976 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8977 Control Assembly: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8978 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > With Electronic Automatic Temperature Control (EATC) Control Assembly: Description and Operation With Electronic Automatic Temperature Control (EATC) The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - 11 push buttons. - a blower speed override thumbwheel for manual input. - a vacuum fluorescent display for displaying set temperature, function and Diagnostic Trouble Codes (DTCs). - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > With Electronic Automatic Temperature Control (EATC) > Page 8981 Control Assembly: Description and Operation With Manual A/C The climate control assembly has three system controls: - The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor control circuit. - The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain. - The blower motor switch controls blower motor speed by adding or bypassing resistors in the heater blower motor switch resistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Page 8982 Control Assembly: Testing and Inspection For further information regarding this component please refer to : Heating and Air Conditioning; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control Control Assembly: Service and Repair With Electronic Automatic Temperature Control REMOVAL 1. Remove the radio chassis. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Disengage the spring clips and remove the instrument panel finish panel. 3. Disconnect the connectors. 4. Remove the screws and remove the electronic automatic temperature control module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8985 5. Remove the electronic automatic temperature control module. 1 Disconnect the electrical connectors. 2 Remove the nuts. 3 Disconnect the vacuum harness connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8986 Control Assembly: Service and Repair Control Assembly Bulbs REMOVAL 1. Remove the climate control assembly. 2. Turn and pull the lamp socket. - Install a new the bulb in the socket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8987 Control Assembly: Service and Repair With Manual Climate Control REMOVAL 1. Remove the radio chassis. For additional information, refer to Radio,Stereo and Compact disc. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Disengage the spring clips and remove the instrument panel finish panel. 3. Disconnect the connectors. 4. Remove the screws and remove the climate control assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8988 5. Disconnect the climate control assembly. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum harness connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 8997 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 9003 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 9008 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 9009 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks Differential Cover: All Technical Service Bulletins Drivetrain - Front Drive Axle Vent Tube Fluid Leaks TSB 05-6-20 04/04/05 FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD FORD: 1995-2001 Explorer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac MERCURY: 1997-2001 Mountaineer This article supersedes TSB 03-05-08 to update the model year applications and to revise the Service Procedure. ISSUE Some Explorer/Mountaineer, Ranger and Explorer Sport/Sport Trac 4x4/AWD vehicles, may exhibit a fluid leak from the front axle vent tube. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation. ACTION Install a revised front axle cover kit. The revised cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE DO NOT FOLLOW THE SERVICE PROCEDURE OUTLINED IN THE DANA/SPICER INSTRUCTION SHEET INCLUDED IN THE COVER KIT. FOLLOW THE TSB SERVICE PROCEDURE. 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. Remove the lower engine splash shield, if equipped. 3. Index-mark the front axle pinion flange and the front driveshaft. 4. Remove the driveshaft bolts and retainers. Discard the driveshaft bolts. 5. Tape the U-joint bearing caps to prevent them from falling off the U-joint. 6. Swing the driveshaft away from the axle pinion yoke and secure out of the way. 7. Remove the three (3) axle support mounting bracket bolts from the axle housing. 8. Position suitable jack beneath axle housing. NOTE PLACE FOLDED SHOP TOWELS OR SUITABLE SOFT MATERIAL OVER TORSION BARS TO PROTECT THE HALFSHAFT BOOTS AND CLAMPS FROM DAMAGE. 9. Remove the two (2) bolts and nuts from the front axle support bushings. Discard the nuts. 10. Carefully lower and position the axle housing until it is resting on the torsion bars. 11. Disconnect the vent hose from the axle housing. 12. Position a drain pan under the axle housing cover. Rotate the axle housing slightly to allow easy access to the axle cover bolts. Remove the axle housing cover and discard. 13. Clean the axle housing cover mounting surface. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 9015 14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing surface. 15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m). 16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the kit (Figure 1). 17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit. 18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque the bolts to 49 lb-ft (66 N.m). 19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106 N.m). 20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m). 21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90 Premium Rear Axle Lubricant. Install fill plug. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050620A 1995-2001 Explorer 1.5 Hrs. 1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac: Install A Revised Axle Cover Kit DEALER CODING CONDITION BASIC PART NO. CODE 4022 D1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 9016 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 9022 14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing surface. 15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m). 16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the kit (Figure 1). 17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit. 18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque the bolts to 49 lb-ft (66 N.m). 19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106 N.m). 20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m). 21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90 Premium Rear Axle Lubricant. Install fill plug. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050620A 1995-2001 Explorer 1.5 Hrs. 1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac: Install A Revised Axle Cover Kit DEALER CODING CONDITION BASIC PART NO. CODE 4022 D1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 > Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 9023 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 9026 Control Module HVAC: Locations Blower Motor Speed Control Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 9027 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 9030 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Page 9031 Control Module HVAC: Description and Operation The blower speed control is located on the evaporator housing in the engine compartment. - The function of the blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - The blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting > Page 9036 Spring Lock Coupling Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 9037 Coupler HVAC: Service Precautions CAUTION: - Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring ; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. - Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. - Support the female fitting with a wrench to prevent the tubes from twisting. - Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. - Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling Coupler HVAC: Description and Operation Spring Lock Coupling Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. - When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. - The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. - These O-ring seals are green in color and are made of special material. - Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling > Page 9040 Coupler HVAC: Description and Operation Peanut Fitting The A/C condenser core uses the peanut shaped refrigerant fittings instead of spring lock couplings. - The male and female blocks of the peanut fitting are retained with a nut. - An O-ring seal is installed around the tube on the male block. - The female block is welded to the tube and is not adjustable. - Support the female fitting with a wrench to prevent twisting of the tubes. - The male block will pivot around the tube to allow for alignment with the female block during assembly. - When correctly assembled the male and female fittings should be flush. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure Coupler HVAC: Service and Repair Spring Lock Coupling Connect and Disconnect Procedure Spring Lock Coupling SPECIAL SERVICE TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling clip. 2. Fit the spring lock coupling disconnect tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 9043 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. - There are three O-ring seals required for the A/C condenser core couplings. - There are two O-ring seals for all other refrigerant tube couplings. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring ; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 9044 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 9045 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-l2-C) or equivalent meeting Ford specification WSH-MlC231-B. 3. Install the O-ring seals. - Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSR-M1C231-B. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 9046 5. Install the A/C tube lock coupling clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 9047 Coupler HVAC: Service and Repair Peanut Fitting Connect and Disconnect Procedure DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 9048 2. Install the O-ring seal. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSR-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When correctly assembled the male and female fittings should be flush. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair Evaporator Case: Service and Repair REMOVAL NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. Replacement of the suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. 1. Remove the suction accumulator, please refer to Heating and Air Conditioning/ See: Accumulator HVAC 2. Disconnect the blower motor and the blower motor resistor electrical connectors. 3. Detach the windshield wiper fluid hose. Using suitable hose pinching pliers, disconnect the heater hoses. 4. Detach the heater control valve vacuum hose. 5. Disconnect the heater control valve vacuum hose and the vacuum supply hose. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 9052 6. Disconnect the condenser to evaporator tube spring lock coupling. 7. Disconnect the vacuum harness connector. Remove the nut. 8. Remove two nuts, one bolt, and the A/C evaporator housing. - Remove the nut located at the bottom of the A/C evaporator housing first. - To remove the A/C evaporator housing, rotate the A/C evaporator housing counterclockwise. Then tip the evaporator core end towards the front of the vehicle. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the refrigerant system with the correct amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. See: Refrigerant Oil Addition. - Install new O-ring seals lubricated in amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. - Lubricate the coolant hoses with MERPOL(R) or plain water only, if needed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 9053 Evaporator Case: Tools and Equipment Heater Hose Disconnect Tool Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 9054 Special Tool(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications Accumulator To Evaporator Core Fitting 35-42 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9058 Evaporator Core: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9059 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9060 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9061 Evaporator Core: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. - The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. - Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9062 Evaporator Core: Testing and Inspection On-Vehicle Leak Test 1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold (gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. if available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg)when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9063 Evaporator Core: Service and Repair REMOVAL NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Perform the Refrigerant Discharging and Recovery Procedure, please refer to Heating and Air Conditioning/Service and Repair/ See: Service and Repair 3. Disconnect the A/C cycling switch. 4. Disconnect the electrical connectors. 1 Disconnect the A/C blower motor electrical connector. 2 Disconnect the A/C blower motor resistor electrical connector. 5. Disconnect the heater core. 1 Disconnect the heater water hoses. 2 Disconnect the heater water control valve vacuum hose. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9064 6. Position the speed control servo aside. 1 Remove the (A) bolt and disconnect the (B) servo electrical connector. 2 Position the speed control servo aside. 7. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside. 8. Disconnect the A/C manifold and tube from the suction accumulator/drier. 9. Disconnect the condenser to evaporator tube. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9065 10. Disconnect the (B) A/C system vacuum harness and the (A) A/C evaporator housing mounting nut inside the vehicle. 11. Remove the A/C evaporator housing, please refer to Heating and Air Condition/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 1 Remove the three underhood and one underdash nuts. 2 Lift the A/C evaporator housing out of the vehicle. 12. Disconnect the suction accumulator/drier from the A/C evaporator core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9066 13. Remove the evaporator housing heat shield. 1 Remove the screw. 2 Remove the clips. 3 Remove the heat shield. 14. Remove the screws attaching the housing cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9067 15. Remove the A/C evaporator core. 1 Separate the evaporator case halves. 2 Lift the A/C evaporator core out. INSTALLATION 1. To install, reverse the removal procedure. - Service the new A/C evaporator core with the correct amount of PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9068 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 9069 Special Tool(s) Set, A/C Fittings Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 9078 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 9084 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9088 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9089 Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: - It is color-coded red. - It has an orifice diameter of 1.6 mm (0.062 inch). - It is located in the A/C evaporator core inlet tube. - It has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. - O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. A new evaporator core orifice assembly must be installed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9090 Expansion Block/Orifice Tube: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the condenser to evaporator tube. 2. Engage the Fixed Orifice Tube Tool to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice. 4. To remove a broken A/C evaporator core orifice, screw the end of the Throttle Remover into the broken A/C evaporator core orifice. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9091 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. - Use PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool. 3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated. 4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9092 Expansion Block/Orifice Tube: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Special Tool(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9104 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9105 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9111 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9112 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9113 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9114 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9115 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9116 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE IN LET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot. the heater core may have an air pocket - the heater core may be plugged - the thermostat is not working correctly. Heater Core-Pressure Test Use Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. For additional information, refer to Cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9117 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9118 Heater Core: Service and Repair REMOVAL 1. Drain the radiator. NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 2. Remove the heater water hoses. 1 Squeeze the clamps and pull the hoses off. 2 Disconnect the vacuum hose from the water control valve. 3. Remove the A/C evaporator core housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 4. Remove the dash board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Remove the Powertrain Control Module (PCM), please refer to Powertrain Management/Computers and Control Systems/Engine Control Module/Service and Repair/ See: Powertrain Management/Computers and Control Systems/Powertrain Control Module/Service and Repair/Procedures 6. Remove the PCM heat sink. 1 Remove the ground strap screw. 2 Remove the heat sink. 7. Remove the heater air plenum nuts from the engine side of the dash panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9119 8. Remove the heater core. 1 Remove the heater core cover to air plenum screws. 2 Lift off the cover. 9. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Be sure to install a new oval foam seal around the heater core inlet and outlet tubes. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications Heater Core Case: Specifications Plenum Chamber Nuts 3.4-4.8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications > Page 9123 Heater Core Case: Service and Repair REMOVAL 1. Remove the dash board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Drain the radiator. 3. Disconnect the heater hoses from the heater core. 4. Remove the evaporator core housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 5. Remove the nuts and remove the plenum chamber. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the hoses and fittings with Rubber Suspension Insulator Lube E25Y-1 9553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9132 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9133 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9139 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9140 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 9141 Heater Hose: Specifications Water heater tube nut fitting 12 - 18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 9142 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications High Pressure Safety Valve HVAC: Specifications A/C Comprssor Pressure Relief valve 3103 kPa Opening Pressure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 9146 High Pressure Safety Valve HVAC: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 9147 Refrigeration System Components - 4.0L (5.0L Similar) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 9148 High Pressure Safety Valve HVAC: Description and Operation An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3,103 kPa [450 psi] and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Peanut Fitting Nut 7-9 Nm A/C Line To Condenser Nut 6.8-9.2 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 9152 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 9153 Spring Lock Coupling Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation For further information regarding this component and the system that it is part of, please refer to: Accumulator HVAC. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 9160 Receiver Dryer: Service and Repair For further information regarding this component and the system that it is part of, please refer to: Accumulator HVAC. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9165 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9166 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9167 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9168 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications System Capacity 30 oz (US) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 9171 Refrigerant: Fluid Type Specifications R-134a Refrigerant Ford Part Number................................................................................................................................. ...................................................Motorcraft YN-19 Ford Specification................................................................................................................................. ....................................................WSH-M17B19-A Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 9172 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 9173 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 9174 Refrigerant: Service and Repair SPECIAL SERVICE TOOL(S) 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing. See: Testing and Inspection/Component Tests and General Diagnostics/Identifying Refrigerants 2. Connect the R-134a A/C refrigerant center to the low and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. For additional information, refer to Manifold Gauge Set Connection. See: Service and Repair/Manifold Gauge Set Connection 3. Perform the Refrigerant Discharging and Recovery Procedure. 4. Once the refrigerant center has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 6. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs, then Perform the Evacuation and Charging Procedure. For additional information, refer to Evacuation and Charging. See: Service and Repair/Evacuation and Charging Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications System Capacity 9 oz (US) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 9179 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) Ford Part Number................................................................................................................................. ................F7AZ-19589-DA (Motorcraft YN-12-C) Ford Specification................................................................................................................................. ...................................................WSH-M1C231-B Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 9180 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. - Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 9181 4. For the A/C condenser core , add 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice. - installation of a new A/C compressor pressure relief valve. - installation of a new refrigerant line. - repair of an O-ring seal leak. - repair of a charge port leak. 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Cycling Switch 324 kPa Close Minimum A/C Cycling Switch 152 kPa Open Minimum Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9185 Refrigerant Pressure Sensor / Switch: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9186 Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9187 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9188 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 9191 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - (SCP) communication. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 9192 Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 9198 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 9199 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 9200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 9201 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 9202 Blower Motor Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay Compressor Clutch Relay: Locations Compressor Clutch Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 9207 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 9208 Compressor Clutch Relay: Locations Compressor Cut-Off Relay Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 9209 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9210 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 9219 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 9225 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 9230 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 9231 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 9237 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 9238 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 9241 Control Module HVAC: Locations Blower Motor Speed Control Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 9242 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 9245 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 9246 Control Module HVAC: Description and Operation The blower speed control is located on the evaporator housing in the engine compartment. - The function of the blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - The blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 9254 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 9261 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the plenum assembly air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 9270 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 9276 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Cycling Switch 324 kPa Close Minimum A/C Cycling Switch 152 kPa Open Minimum Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9280 Refrigerant Pressure Sensor / Switch: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9281 Manual A/C Electrical Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9282 Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9283 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 9286 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - (SCP) communication. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 9287 Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 9291 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 9292 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 9293 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 9297 Refrigeration System Components - 4.0L (5.0L Similar) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 9298 Service Port HVAC: Description and Operation The high-pressure service gauge port valve is located on the front A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A new Schrader-type valve core can be installed if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valve after repairing the refrigerant system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 9302 Component Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 9303 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 9304 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information Vacuum Harness HVAC: Customer Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information > Page 9309 Vacuum Harness HVAC: Technician Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 9310 Vacuum Harness HVAC: Service and Repair VACUUM HOSE REPAIR - MINI TUBE Vacuum Pump Kit SPECIAL SERVICE TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT POSSIBLE INJURY. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch service vacuum hose section. 6. Shake the service joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Tester or equivalent. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 9311 Vacuum Tester Kit Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment INSPECTION AND REPAIR AFTER A SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPLOYMENT WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: After diagnosing or repairing a SRS the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When any deployable device (driver air bag, passenger air bag, seat side air bag, safety belt pretensioner, etc.) or combination of devices are deployed and/or the ECS module has the DTC B1231 (Crash Data Memory Full) in memory, the repair of the vehicle's supplemental restraint system (SRS) is to include the removal of all deployed devices and installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new ECS module. 2. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 3. When the driver air bag module has deployed a new clockspring must be installed. 4. Inspect the entire vehicle for damage, including the following components: - steering column. - instrument panel knee bolsters and mounting points. - instrument panel braces and brackets. - instrument panel and mounting points. - seats and seat mounting points. - safety belts, safety belt buckles, and safety belt retractors - supplemental restraint system (SRS) wiring, wiring harnesses, and connectors. 5. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 9317 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters, child safety seat tether attachments (if equipped), and attaching hardware should be inspected after any collision. New belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or incorrect operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: . 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9323 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9324 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9325 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9326 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9327 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9328 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Air Bag Harness: Customer Interest Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Article No. 03-24-1 12/08/03 ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994 AND/OR B1998 FORD: 1999-2001 EXPLORER SPORT, EXPLORER MERCURY: 1999-2001 MOUNTAINEER This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage. ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998 stored in memory. This may be due to a high resistance or poor connections in the side air bag (SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles equipped with, or without, side air bags. ACTION To service, install an overlay harness which incorporates soldered terminals and tin wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation instructions and illustrations are included in the kit. SERVICE PROCEDURE FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z" 1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction sheet included in the kit. FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D" 1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet included in the kit. ^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB ^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC ^ 1999-2000 2DR Explorer XL2Z-14B455-BC ^ 2001 2DR Explorer 1L2Z-14B455-AC Reference section 501-20A of the appropriate model year Workshop Manual for additional information if needed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 > Page 9338 Labor Operation Claiming Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-01-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B455 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System Air Bag Lamp ON/DTC B1994/B1998 Air Bag Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Article No. 03-24-1 12/08/03 ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994 AND/OR B1998 FORD: 1999-2001 EXPLORER SPORT, EXPLORER MERCURY: 1999-2001 MOUNTAINEER This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage. ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998 stored in memory. This may be due to a high resistance or poor connections in the side air bag (SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles equipped with, or without, side air bags. ACTION To service, install an overlay harness which incorporates soldered terminals and tin wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation instructions and illustrations are included in the kit. SERVICE PROCEDURE FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z" 1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction sheet included in the kit. FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D" 1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet included in the kit. ^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB ^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC ^ 1999-2000 2DR Explorer XL2Z-14B455-BC ^ 2001 2DR Explorer 1L2Z-14B455-AC Reference section 501-20A of the appropriate model year Workshop Manual for additional information if needed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System Air Bag Lamp ON/DTC B1994/B1998 > Page 9344 Labor Operation Claiming Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-01-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B455 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module Bracket 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 9348 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 9349 Air Bag Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 9350 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 9351 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL WARNING: ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the right hand cowl side trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9354 3. Disconnect the Restraints Control Module (RCM). 1 Slide the two RCM electrical connector locking clips down to disengage them. 2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical connectors. 4. Remove the RCM with bracket. 1 Remove the three RCM bracket retaining bolts. 2 Remove the RCM with bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9355 1. Follow the removal procedure in reverse order. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9356 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9357 LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J" Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts must be installed as outlined in this procedure. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications Air Bag Sliding Contact: Specifications Steering Column Fore And Aft Nuts 15 Nm Lower Steering Column Opening Finish Panel Reinforcement 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9361 Air Bag Sliding Contact: Diagrams With Auxiliary Controls Without Auxiliary Controls Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9362 Air Bag Sliding Contact: Description and Operation The air bag sliding contact: ^ is mounted on the steering column, behind the steering wheel. ^ continuously transfers electrical signals from the driver air bag module to the Restraints Control Module (RCM). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9363 Air Bag Sliding Contact: Service and Repair REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag module. 3. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation when the air bag sliding contact is removed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9364 5. Remove the lower steering column opening finish panel. 1 Remove the retaining screws and position the hood release handle out of the way. 2 Remove the two retaining screws from the lower steering column opening finish panel. 3 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 6. Remove the four retaining bolts and remove the lower steering column opening finish panel reinforcement. 7. Loosen, but do not remove, the four steering column to instrument panel retaining bolts enough to remove the upper steering column shroud (two shown). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9365 8. Remove the lower steering column shroud. 1 If equipped, remove the tilt wheel handle and shank. 2 Remove the three screws. 3 Remove the lower steering column shroud. 9. Remove the ignition switch lock cylinder. 1 Position the ignition switch lock cylinder to the RUN position. 2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch lock cylinder outward. 10. Remove the upper steering column shroud. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9366 11. Remove the Passive Anti-Theft System (PATS) transmitter. 1 Remove the PATS transmitter retaining screw. 2 Position the PATS transmitter out of the way. 12. Remove the key-in-ignition warning indicator switch. 13. Remove the two air bag sliding contact wire connectors from the wire connector bracket and disconnect them. 14. Remove the wire harness from the two holders (one shown). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9367 15. Release the lower air bag sliding contact retaining clip. 16. Remove the air bag sliding contact. 1 Release the remaining two air bag sliding contact retaining clips. 2 Remove the air bag sliding contact. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Specifications > Page 9368 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Impact Sensor: Recalls Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9381 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9382 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9383 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9384 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9385 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Impact Sensor: All Technical Service Bulletins Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9395 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9396 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9397 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9398 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9399 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 9400 Impact Sensor: Specifications Side Crash Sensor 12 Nm Front Crash Sensor 10.2-13.8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 9403 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor Impact Sensor: Service and Repair Front External Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill and radiator opening cover. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 9406 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 9407 Impact Sensor: Service and Repair Side Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the B-pillar lower trim panel with scuff plates. NOTE: ^ Four door is shown, two door is similar. ^ The front seat has been removed for clarity. 3. Remove the side crash sensor. 1 Disconnect the side crash sensor electrical connector. 2 Remove the two retaining bolts. 3 Remove the side crash sensor with bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 9408 WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Recalls for Side Air Bag: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Side Air Bag: Recalls Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Recalls for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Recalls for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9421 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Recalls for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9422 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Recalls for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9423 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Recalls for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9424 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Recalls for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9425 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Side Air Bag: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Side Air Bag: All Technical Service Bulletins Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9435 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9436 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9437 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9438 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Side Air Bag: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9439 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Page 9440 Side Air Bag: Specifications AdjusterLatch/Pivot Cover Screw 1.6-2.2 Nm Battery Ground Cable Bolt 7-10 Nm Center Occupant Safety Belt Bolt 30-40 Nm Driver Seat Module Screws 12 Nm Front/Rear Seat Backrest Latch Bolts 47-63 Nm Front Seat Back Pad Adjusting Pump Bolt 11-14 Nm Front Seat Cushion Side Cover Screws 1.6-2.2 Nm Front Seat Inboard Pivot Bolt 19-26 Nm Front Seat Track To Floor Bolts 21-28 Nm Inboard Safety Belt Bracket Bolt 38-44 Nm Latch Handle Screws 1.6-2.2 Nm Link Arm Nut 30-40 Nm Rear Outboard Bolt 30-40 Nm Rear Outboard Nut 30-40 Nm Rear Seat Back Inboard/Outboard Pivot Bolts 38-44 Nm Rear Seat Riser To Floor Nuts 30-40 Nm Rear Seat Riser Pivot Bolts 38-44 Nm Rear Seat Link Bolt 30-40 Nm Rear Seat To Floor Bolts 30-40 Nm Safety Belt Buckle Bracket To Floor Nuts 34-46 Nm Seat Cushion To Adjuster Latch Bolts, Rear Seat 38-44 Nm Seat Track To Seat Cushion Bolts 17-23 Nm Side Air Bag Nuts 8 Nm Slide Bar To Floor Bolt 40 Nm Slide Bar To Seat Track Bolt 7.5-10.5 Nm Slide Bar To Seat Track Nut 7.5-10.5 Nm 40% Seat Inboard Pivot Bolts 23-32 Nm 50% Seat Cushion To Seat Hinge Bolts 7-11 Nm 50/50 Seat Back Latch Bolt 30-46 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Page 9441 60% Front Seat Armrest Bolt 30-35 Nm 60% Seat Cushion Outboard Side Bolster Screw 1.6-2.2 Nm 60% Seat Inboard Pivot Cover Bolt 1.6-2.2 Nm Side Air Bag Module 8 Nm Seat Back Pivot Bolt 29 Nm Seat Back Recliner Bolts 52 Nm Track To Cushion Frame 20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Technical Service Bulletins > Page 9442 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information Side Air Bag: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 9445 Side Air Bag: Vehicle Damage Warnings WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module Side Air Bag: Service and Repair Side Air Bag Module REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ When replacing the side air bag after deployment, refer to information concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Front driver seat is shown, passenger seat is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the seat from the vehicle. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 3. Disconnect the seat motor electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9448 4. Remove the four bolts (two shown) and the seat track from the seat bottom. 5. Disconnect the power seat switch electrical connector. 6. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim panel retaining screw. NOTE: Release all tension from the manual lumbar support cable. 7. Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel from the seat bottom frame. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9449 8. Remove the lower seat trim panel. 1 Disconnect the heated seat switch (if equipped). 2 Remove the lower seat trim panel. 9. Remove the push pin holder from the seat bottom frame for the lumbar support cable. 10. Separate the lumbar support cable assembly. 1 Separate the lumbar support case assembly by sliding apart. 2 Remove the cable end ball from the cable end retainer and separate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9450 11. Remove the push pin retaining the heated seat back electrical connector to the seat bottom frame. 12. Disconnect the heated seat back electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9451 13. Remove the side air bag electrical connector and wire harness push pins from the seat bottom frame. 14. Remove the push pin from the side air bag electrical connector. 15. Remove the two retaining bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9452 16. Laying the seat on its other side, remove the retaining bolt for the seat pivot, being careful not to damage the seat pivot, cable or any of the wires. CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 17. Remove the seat back from the seat bottom. 1 Pull the heated seat wire harness through the seat bottom. 2 Pull the lumbar support cable through the seat bottom. 3 Pull the side air bag module wire harness through the seat bottom. 4 Remove the seat back from the seat bottom. 18. Separate the seat back trim cover lower J-clip. 19. Remove and discard the hog rings from the two swing rods (one shown). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9453 20. Slide the swing rods out of the seat back trim cover. 21. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 22. Unzip the side air bag deployment chute. 23. Roll the seat back cover and side air bag deployment chute to completely expose the side air bag module and mounting bracket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9454 24. Remove the side air bag wire harness tie strap retainer. 25. Position the side air bag module aside, through the seat back cushion opening. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 26. Remove the side air bag module. 1 Slide the side air bag module electrical connector locking clip to disengage it. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. INSTALLATION WARNING: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9455 ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 2. Make sure the electrical connector is securely fastened to the side air bag module. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9456 3. Install the side air bag module onto the front seat back frame mounting bracket, making sure the side air bag wiring harness is located behind the seat backrest frame and side air bag module mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket. 2 Install the side air bag module retaining nut. 3 Install the side air bag module retaining nut. 4 Install the side air bag module retaining nut. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 4. Tie-strap the side air bag module wire harness to the seat back frame. 5. Unroll the seat back trim cover, to position the deployment chute around the side air bag module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9457 6. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 7. Zip the air bag deployment chute completely closed, then position the zipper tail at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: Be sure the side air bag deployment chute is properly positioned, before proceeding. 8. Unroll the seat back trim cover to the bottom row of hog rings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9458 9. Install the swing rods back into the seat back trim cover sleeves. 10. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog rings, position the top of the swing rods under the listing wire in the seat back pad. NOTE: The seat back trim cover has been inverted for clarity. 11. Install new hog rings onto the swing rods (one shown). 12. Pull the seat back rest trim cover completely down and connect the hook and loop fastener to the seat back cushion. 13. Route the seat back heating element wire harness (if equipped). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9459 14. Reattach the seat back trim cover lower J-clips. 15. Position the seat back to the seat bottom and route the wires and cables. 1 Pull the side air bag module wire harness through the seat bottom. 2 Pull the lumbar support cable through the seat bottom. 3 Pull the heated seat wire harness through the seat bottom. 16. Align the seat back to the seat bottom. Install the bolt and tighten to specification. CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 17. Install the two bolts and tighten to specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9460 18. Install the push pin onto the side air bag electrical connector. 19. Route the side air bag module electrical connector and wire harness, then install the push pins. 20. Connect the heated seat wire connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9461 21. Route the heated seat wire harness and install the push pin. 22. Connect the lumbar support cable assembly. 1 Install the cable end ball to the cable end retainer. 2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot. 23. Install the push pin holder to the seat bottom frame for the lumbar support cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9462 24. Install the seat bottom lower side shield into the seat bottom frame. 1 Connect the heated seat switch (if equipped). 2 Insert the lower side shield clips into the seat bottom frame. 25. Install the seat bottom lower side shield retaining screw and the lumbar support handle. 26. Connect the power seat switch electrical connector. 27. Position the seat track to the seat bottom frame. Install the four bolts (two shown) and tighten to specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9463 28. Connect the seat motor electrical connector. 29. Install the seat into the vehicle. 30. Connect the battery ground cable. 31. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9464 Side Air Bag: Service and Repair Side Air Bag Wiring Harness Limited Seat REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ A side air bag repair is made by installing a new component only. If a part is replaced and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information refer to Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Disassembly and Assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9465 3. Unhook the trim cover J-clip. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Roll the seat backrest trim cover to the first row of hog rings. 5. Remove and discard the hog rings. 6. Roll the seat backrest trim cover to the second row of hog rings. 7. Remove and discard the hog rings. 8. Roll the seat backrest trim cover to the side air bag deployment chute. 9. Unzip the side air bag deployment chute. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9466 10. Roll the seat backrest trim cover to the third row of hog rings. 11. Remove and discard the hog rings. 12. Remove the side air bag wiring harness wire tie. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9467 13. Through the seat backrest cushion opening, position the side air bag module aside. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 14. Remove the side air bag module. 1 Release the side air bag module electrical connector clip. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 15. Remove the side air bag wiring harness. ^ Disconnect the pin-type retainers from the seat backrest frame. NOTE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9468 ^ Sport bucket seat shown; Limited seat similar. ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. ^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side air bag wiring harness. Connect the pin-type retainer to the seat backrest frame. NOTE: ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. ^ Sport bucket seat shown; Limited seat similar. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9469 4. Install the side air bag module onto the front seat back frame mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket being sure the side air bag wiring harness is located behind the seat backrest frame. 2 Install the side air bag module retaining nut. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Be sure the side air bag wiring harness is not pinched between the side air bag module and mounting bracket. 5. Tie-strap the side air bag module wire harness to the seat back frame. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9470 6. Unroll the seat backrest trim cover to the third row of hog rings. 7. Install the hog rings. 8. Roll the seat back trim cover to position the deployment chute around the side air bag module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9471 9. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 10. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next step. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9472 11. Unroll the seat backrest trim cover to the second row of hog rings. 12. Install the hog rings. 13. Unroll the seat backrest trim cover to the bottom row of hog rings. 14. Install the hog rings. 15. Hook the trim cover clip. NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and off-set from the lower seat backrest trim cover J-clip. 16. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited, Disassembly and Assembly. 17. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Prove out the air bag system. For additional information, refer to Air Bag Systems. 19. Check the restraint system for proper operation. Sport Bucket Seat REMOVAL Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9473 WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ A side air bag repair is made by installing a new component only. If a part is replaced and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited or Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual, Disassembly and Assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9474 3. Unhook the trim cover J-clip. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Remove the seat backrest trim cover swing rods. 1 Remove and discard the hog rings. 2 Remove the seat backrest trim cover cushion swing rods. 5. Roll the seatback trim cover in an inside out fashion to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9475 6. Unzip the side air bag deployment chute. 7. Roll the seat backrest cover and side air bag deployment chute to completely expose the side air bag bracket and side air bag module. 8. Remove the side air bag wiring harness wire tie. 9. Through the seat backrest cushion opening, position the side air bag module aside. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9476 10. Remove the side air bag module. 1 Release the side air bag module electrical connector clip. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 11. Remove the side air bag wiring harness. ^ Disconnect the pin-type retainers from the seat backrest frame. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. ^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9477 1. Install the side air bag wiring harness. Connect the pin-type retainer to the seat backrest frame. NOTE: ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. ^ Sport bucket seat shown; Limited seat similar. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. 4. Install the side air bag module onto the front seat back frame mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket being sure the side air bag wiring harness is located behind the seat backrest frame. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9478 2 Install the side air bag module retaining nut. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Be sure the side air bag wiring harness is not pinched between the side air bag module and mounting bracket. 5. Tie-strap the side air bag module wire harness to the seat back frame. 6. Roll the seat back trim cover to position the deployment chute around the side air bag module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9479 7. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 8. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next step. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9480 9. If equipped, install the seat backrest trim cover swing rods. 1 Position the seat backrest trim cover and install the swing rods through the sleeves. 2 Install the hog rings. NOTE: Make sure that the top of the swing rod is positioned beneath the listing wire near the middle row of hog rings. 10. Connect the hook and loop fastener to the seat backrest trim cover. 1 Pull the seat backrest trim cover completely down. 2 Reach up inside the seat backrest and grab the plastic above the hook and loop. Remove enough plastic to expose the hook and loop. 11. Hook the trim cover clip. NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and off-set from the lower seat backrest trim cover J-clip. 12. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited, Disassembly and Assembly. 13. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 14. Prove out the air bag system. For additional information, refer to Air Bag Systems. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9481 15. Check the restraint system for proper operation. Except Limited and Sport Bucket Seats REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ A side air bag repair is made by installing a new component only. If a part is replaced and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited or Seat-Front Bucket, Manual. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual, Disassembly and Assembly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9482 3. Unhook the trim cover J-clip. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Unzip the side air bag deployment chute. 5. Remove the side air bag wiring harness wire tie. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9483 6. Through the seat backrest cushion opening, position the side air bag module aside. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 7. Remove the side air bag module. 1 Release the side air bag module electrical connector clip. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 8. Remove the side air bag wiring harness. ^ Disconnect the pin-type retainers from the seat backrest frame. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9484 NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. ^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO FOLLOW THESE INSTMCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side air bag wiring harness. ^ Connect the pin-type retainer to the seat backrest frame. NOTE: ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. ^ Sport bucket seat shown; Limited seat similar. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9485 4. Install the side air bag module onto the front seat back frame mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket being sure the side air bag wiring harness is located behind the seat backrest frame. 2 Install the side air bag module retaining nut. 3 Install the side air bag module retaining nut. 4 Install the side air bag module retaining nut. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Be sure the side air bag wiring harness is not pinched between the side air bag module and mounting bracket. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9486 5. Tie-strap the side air bag module wire harness to the seat back frame. 6. Roll the seat back trim cover to position the deployment chute around the side air bag module. 7. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPELY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 9487 8. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next step. 9. Hook the trim cover clip. NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and off-set from the lower seat backrest trim cover J-clip. 10. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited, Disassembly and Assembly. 11. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Prove out the air bag system. For additional information, refer to Air Bag Systems. 13. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 9491 Malfunction Lamp / Indicator: Description and Operation If an air bag system DTC or malfunction is detected, the air bag indicator is illuminated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module Bracket 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 9496 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 9497 Air Bag Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 9498 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 9499 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL WARNING: ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the right hand cowl side trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9502 3. Disconnect the Restraints Control Module (RCM). 1 Slide the two RCM electrical connector locking clips down to disengage them. 2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical connectors. 4. Remove the RCM with bracket. 1 Remove the three RCM bracket retaining bolts. 2 Remove the RCM with bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9503 1. Follow the removal procedure in reverse order. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9504 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 9505 LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J" Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts must be installed as outlined in this procedure. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9511 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9512 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9513 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9514 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9515 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9516 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation Attaching Safety Seats With Tether Straps Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Attach a tether strap anchor bracket to the rear floor by using a tether anchor kit, available at no charge from any Ford or Lincoln-Mercury dealership. Carefully read and follow the instructions provided with the kit for installation of the child tether strap anchor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Specifications Safety Belt: Specifications Rear Seat Center Occupant Safety Belt And Retractor Bolt 40 Nm Safety Belt Anchor Bolts 40 Nm Safety Belt Guide To Floor Bolt 40 Nm Safety Belt Guide To Seat Track Bolt 9.0 Nm Safety Belt Guide To Seat Track Nut 9.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning Safety Belt: Service and Repair Safety Belt Cleaning 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning > Page 9526 Safety Belt: Service and Repair Safety Belt With Anchor Plate Thread Damage 1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt anchor plate with a 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with the repair parts indicated in the Safety Belt Parts Replacement Guidelines. See: Parts Replacement Chart 6. When repairing a multiple belt and attachment, install the nut to the bolt in the tunnel area from the underside of the floorpan. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning > Page 9527 Safety Belt: Service and Repair Replacement Of The Weld Nut And Reinforcement 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut only or the weld nut and reinforcement and weld nut are missing. If the B or C- or D- pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld nut clearance bole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder 106-00053 to plug weld the nut in place at the two 8 mm (5/16 in)diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning > Page 9528 Safety Belt: Service and Repair Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit SPECIAL SERVICE TOOLS 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning > Page 9529 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning > Page 9530 Safety Belt: Service and Repair Safety Belt Cleaning 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN. Safety Belt With Anchor Plate Thread Damage 1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt anchor plate with a 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with the repair parts indicated in the Safety Belt Parts Replacement Guidelines. See: Parts Replacement Chart 6. When repairing a multiple belt and attachment, install the nut to the bolt in the tunnel area from the underside of the floorpan. Replacement Of The Weld Nut And Reinforcement 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut only or the weld nut and reinforcement and weld nut are missing. If the B or C- or D- pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld nut clearance bole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder 106-00053 to plug weld the nut in place at the two 8 mm (5/16 in)diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit SPECIAL SERVICE TOOLS 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning > Page 9531 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Safety Belt Tongue Rotated on Belt 1. Fold the safety belt as indicated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Cleaning > Page 9532 2. Pull the safety belt tongue over the fold in the safety belt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement Technical Service Bulletin # 00S21 Date: 001001 Recall - Seat Belt Buckle Inspection/Replacement 00521 SAFETY RECALL Certain 2000 Model Year Cars and Light Trucks - Seat Belt Buckle Assembly Inspection ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Owner Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9541 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9542 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9543 Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS If a part needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel which will be at owner's expense. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9544 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Order your parts requirement through normal order processing channels. Not all vehicles will require new parts. Please perform the insDection before ordering parts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9545 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9546 Parts Application Chart: Seat Salt Buckle Assembly DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information ATTACHMENT Ill Safety Recall 00S21 SEAT BELT BUCKLE INSPECTION AND REPLACEMENT AFFECTED VEHICLES: CERTAIN 2000 MODEL YEAR CONTOUR, ESCORTIZX2, TOWN CAR, EXPLORERIMOUNTAINEER, F-SERIES (LIGHT DUTY), RANGER, VILLAGER AND WINDSTAR (EUROPE ONLY) OVERVIEW The affected vehicles in this program will require inspection of seat belt buckles in certain seating positions to determine if replacement is necessary. ^ Not all seat belt buckles will require ins~ection. Only the seat belts identified in the Build Date Code Inspection chart will need to be inspected. ^ The build date code is located on the seat belt buckle end. A plastic anchor boot covers the build date code on some affected seat belt buckles. These vehicles will require removal and disassembly of the seat belt buckle, and are identified in the Build Date Code Inspection chart. SERVICE PROCEDURE 1. Refer to the Build Date Code Inspection chart on page 3 to identify the seat belt buckle(s) that require inspection. 2. Inspect the build date code located on the seat belt buckle end(s). Refer to Figure 1. If the build date code is covered by the plastic anchor boot, proceed as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9547 ^ Remove the seat belt buckle from the vehicle. Refer to the service procedures in section 501-20A of the appropriate Workshop Manual. ^ Separate the seat belt buckle from the plastic anchor boot to access the build date code. If the plastic anchor boot is damaged during separation, replace the seat belt buckle assembly regardless of the build date code. 3. Compare the seat belt buckle date code to the code listed in the Build Date Code Inspection chart. NOTE: On certain vehicles, you will receive a retractor and buckle as an assembly. Only the buckle is to be replaced under this program. The retractor portion of the new assembly should be discarded. NOTE: Apply Ford Threadlock 262 (E2FZ-19554B) or equivalent to fasteners when installing seat belt buckle assemblies. ^ If the build date code matches that listed in the chart, replace the seat belt buckle assembly. Refer to the service procedures in section 501-20A of the appropriate Workshop Manual. ^ If the build date code does not match those listed in the chart, the seat belt buckle does not require replacement. Assemble and install the seat belt buckle, if removed. Refer to the service procedures in section 501-20A of the appropriate Workshop Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9548 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9549 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9550 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9551 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9552 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9553 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Recalls for Safety Belt Buckle: > NHTSA00V228001 > Aug > 00 > Recall 00V228001: Seat Belt Buckle Defect Safety Belt Buckle: Recalls Recall 00V228001: Seat Belt Buckle Defect Passenger vehicles, light duty trucks, sport utility vehicles, and mini vans equipped with TRW seat belt buckle assemblies. The buckle base of these seat belt assemblies were not properly heat treated and therefore do not pass the load bearing requirement of Federal Motor Vehicle Safety Standard No. 209, "Seat Belt Assemblies." In the event of a vehicle crash, the occupant may not be properly restrained. Dealers will inspect the date code on certain seat belt buckles of your vehicle and replace all seat belt buckles that fall within the suspect date code range. Owner notification is expected to begin during October 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement Technical Service Bulletin # 00S21 Date: 001001 Recall - Seat Belt Buckle Inspection/Replacement 00521 SAFETY RECALL Certain 2000 Model Year Cars and Light Trucks - Seat Belt Buckle Assembly Inspection ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Owner Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9563 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9564 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9565 Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS If a part needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel which will be at owner's expense. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area. Attachment II - Labor and Parts Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9566 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Order your parts requirement through normal order processing channels. Not all vehicles will require new parts. Please perform the insDection before ordering parts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9567 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9568 Parts Application Chart: Seat Salt Buckle Assembly DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information ATTACHMENT Ill Safety Recall 00S21 SEAT BELT BUCKLE INSPECTION AND REPLACEMENT AFFECTED VEHICLES: CERTAIN 2000 MODEL YEAR CONTOUR, ESCORTIZX2, TOWN CAR, EXPLORERIMOUNTAINEER, F-SERIES (LIGHT DUTY), RANGER, VILLAGER AND WINDSTAR (EUROPE ONLY) OVERVIEW The affected vehicles in this program will require inspection of seat belt buckles in certain seating positions to determine if replacement is necessary. ^ Not all seat belt buckles will require ins~ection. Only the seat belts identified in the Build Date Code Inspection chart will need to be inspected. ^ The build date code is located on the seat belt buckle end. A plastic anchor boot covers the build date code on some affected seat belt buckles. These vehicles will require removal and disassembly of the seat belt buckle, and are identified in the Build Date Code Inspection chart. SERVICE PROCEDURE 1. Refer to the Build Date Code Inspection chart on page 3 to identify the seat belt buckle(s) that require inspection. 2. Inspect the build date code located on the seat belt buckle end(s). Refer to Figure 1. If the build date code is covered by the plastic anchor boot, proceed as follows: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9569 ^ Remove the seat belt buckle from the vehicle. Refer to the service procedures in section 501-20A of the appropriate Workshop Manual. ^ Separate the seat belt buckle from the plastic anchor boot to access the build date code. If the plastic anchor boot is damaged during separation, replace the seat belt buckle assembly regardless of the build date code. 3. Compare the seat belt buckle date code to the code listed in the Build Date Code Inspection chart. NOTE: On certain vehicles, you will receive a retractor and buckle as an assembly. Only the buckle is to be replaced under this program. The retractor portion of the new assembly should be discarded. NOTE: Apply Ford Threadlock 262 (E2FZ-19554B) or equivalent to fasteners when installing seat belt buckle assemblies. ^ If the build date code matches that listed in the chart, replace the seat belt buckle assembly. Refer to the service procedures in section 501-20A of the appropriate Workshop Manual. ^ If the build date code does not match those listed in the chart, the seat belt buckle does not require replacement. Assemble and install the seat belt buckle, if removed. Refer to the service procedures in section 501-20A of the appropriate Workshop Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9570 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9571 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9572 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9573 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9574 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > 00S21 > Oct > 00 > Recall - Seat Belt Buckle Inspection/Replacement > Page 9575 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt Buckle: > NHTSA00V228001 > Aug > 00 > Recall 00V228001: Seat Belt Buckle Defect Safety Belt Buckle: All Technical Service Bulletins Recall 00V228001: Seat Belt Buckle Defect Passenger vehicles, light duty trucks, sport utility vehicles, and mini vans equipped with TRW seat belt buckle assemblies. The buckle base of these seat belt assemblies were not properly heat treated and therefore do not pass the load bearing requirement of Federal Motor Vehicle Safety Standard No. 209, "Seat Belt Assemblies." In the event of a vehicle crash, the occupant may not be properly restrained. Dealers will inspect the date code on certain seat belt buckles of your vehicle and replace all seat belt buckles that fall within the suspect date code range. Owner notification is expected to begin during October 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Page 9580 Safety Belt Buckle: Specifications Driver Seat Safety Belt Buckle Nut 40 Nm Front Seat Safety Belt Buckle Bolt 40 Nm Rear Seat Safety Belt Buckle Assembly Rear Nuts 48 Nm Rear Seat Safety Belt Buckle Front Nuts 40 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Page 9581 Safety Belt Buckle: Locations Buckles, Four-Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Page 9582 Buckles, Two-Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Technical Service Bulletins > Page 9583 Safety Belt Buckle: Description and Operation When replacing safety belt buckle or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts Catalog. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Bucket Seats Safety Belt Buckle: Service and Repair Bucket Seats Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the floor console. 2. Move the seat forward and use Safety Belt Bolt Bit to remove the slide bar bolt. 3. Remove the front seat. 4. Remove the safety belt slide bar. 1 Disconnect the electrical connector (LH only). 2 Remove the nut. 3 Remove the bolt. 4 Remove the slide bar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Bucket Seats > Page 9586 5. Remove the safety belt buckle. 1 Clamp the slide bar in a suitable vise. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. NOTE: Clamp the slide bar collar in a vise along the break line only. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Bucket Seats > Page 9587 Safety Belt Buckle: Service and Repair Rear Seat Four-Door REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the rear seats. 2. Remove the rear safety belt buckle assembly. 1 Remove the nuts. 2 Remove the rear safety belt buckle assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Two-Door REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the rear seats. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Bucket Seats > Page 9588 2. Remove the rear safety belt buckles. 1 Remove the nuts. 2 Remove the rear safety belt buckles. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt extensions are only available with black webbing. There are two extension assemblies available, one for the front seating positions and one for the rear seating positions and they are not interchangeable. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if safety belt is too short for you when fully extended. Do not use extension to change the fit of the shoulder belt across the torso. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Shoulder Safety Belt Height Adjuster Bolts 40 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation Seat Belt Height Adjuster: Service and Repair Removal and Installation Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL 1. Remove the B-pillar trim panel. 2. Remove the height adjuster cover. 3. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the shoulder safety belt height adjuster. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 9597 1. Use Safety Belt Bolt Bit and install the shoulder safety belt height adjuster. 2. Install the height adjuster cover. 3. Install the B-pillar trim panel. 4. Check the restraint system for proper operation. Two-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL 1. Remove the quarter trim panel. 2. Remove the height adjuster cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 9598 3. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the shoulder safety belt height adjuster. INSTALLATION 1. Use Safety Belt Bolt Bit and install the shoulder safety belt height adjuster. 2. Install the height adjuster cover. 3. Install the quarter trim panel. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 9599 Seat Belt Height Adjuster: Service and Repair General Procedures D-Ring Installation Kit SPECIAL SERVICE TOOLS 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 9600 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Locations > Page 9604 Seat Belt Reminder Lamp: Description and Operation The safety belt warning indicator is powered through the GEM/CTM module. When the ignition key is turned on, the indicator illuminates for four to eight seconds even if the safety belt is buckled. For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Locations > Page 9605 Seat Belt Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Specifications Seat Belt Retractor: Specifications Rear Seat Center Occupant Safety Belt And Retractor Bolt 40 Nm Safety Belt Retractor Bolts 40 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Specifications > Page 9609 Seat Belt Retractor: Description and Operation The shoulder harness retractor is designed to let the webbing move freely in or out at all times, except during vehicle hard braking, hard cornering or an impact of 8 km/h (5 mph) or more, when it is automatically locked by a mechanically actuated inertia sensor. DUAL LOCKING MODE RETRACTORS NOTE: When replacing a dual locking mode retractor, the retractor should be checked to make sure it is not in the Automatic Locking Retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the dual locking mode system. The Emergency Locking Retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in an outboard seating position or when a tight belt fit is desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE OR ANY OTHER SAFETY BELT FUNCTION IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. This vehicle has a safety belt system with an energy management feature at the front seating positions to help further reduce the risk of injury in the event of a head-on collision. This safety belt system has a retractor assembly that is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on occupant's chest. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Specifications > Page 9610 Seat Belt Retractor: Testing and Inspection WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. 1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in the safety belt, with the seat in the full down and rearmost position, seat back in an upright position, and if applicable, the D-ring adjusted in the full down position. 2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor (ALR) feature. Then allow the belt to retract freely in the ALR mode, and the retractor force set the proper belt tightness. 3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new belt and retractor assembly. The safety belt should remain locked in the ALR mode across an empty seat. 4. To verify that the safety belt still automatically disengages from the ALR mode properly, with the D-ring adjusted to the full up position, if applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and retractor assembly must be installed. The safety belt should extract freely. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor Seat Belt Retractor: Service and Repair B-Pillar Retractor Two-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the quarter trim panel. 2. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the front safety belt retractor. 2. Install the quarter trim panel. 3. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 9613 Driver Side and Outside Passenger,Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the B-pillar trim panel. 2. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the front safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the front safety belt retractor. 2. Install the B-pillar trim panel. 3. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 9614 Seat Belt Retractor: Service and Repair C-Pillar Retractor Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the quarter trim panel. 2. Remove the safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the safety belt retractor. 2. Install the quarter trim panel. 3. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 9615 Two-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the quarter trim panel. 2. Remove the safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the safety belt retractor. 2. Install the quarter trim panel. 3. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 9616 Seat Belt Retractor: Service and Repair Rear Seat Retractor and Buckle Assembly, Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Fold the rear seat down to load floor position. 2. Remove the rear safety belt buckle and retractor assembly. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the rear safety belt buckle and retractor assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Impact Sensor: Recalls Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9630 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9631 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9632 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9633 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > 00S17 > Jun > 00 > Recall - Side Airbag Sensor Replacements > Page 9634 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA00V179000 > Jun > 00 > Recall 00V179000: Inadvertent Side Air Bag Deployment Impact Sensor: All Technical Service Bulletins Recall 00V179000: Inadvertent Side Air Bag Deployment Vehicle Description: 4-door sport utility vehicles equipped with side airbags. The subject vehicles have a revised level side crash sensor that could deploy the side air bag if the ignition key is in the "run" position and the seatbelt webbing is forcibly extracted from a locked retractor with a jerking motion. Inadvertent side air bag deployment could cause personal injury to the seat occupant. Dealers will replace the side crash sensors with a revised design that will reduce the likelihood of an unexpected side air bag deployment. Owner notification is expected to begin during July 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall Side Airbag Sensor Replacements Technical Service Bulletin # 00S17 Date: 000601 Recall - Side Airbag Sensor Replacements 00S17 SAFETY RECALL Certain 2000 Model Year Explorer/Mountaineer - Side Airbag Crash Sensor Replacements Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall Side Airbag Sensor Replacements > Page 9644 Attachment I - Administrative Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements OASIS OASIS will be activated for this recall Thursday, June 29, 2000. You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC). Also, correct other eligible vehicles which are brought to your dealership. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall Side Airbag Sensor Replacements > Page 9645 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. RENTAL CARS Rental cars are authorized for sold units. Ford will pay for a loaner or rental vehicle for a maximum of seven (7) days except for fuel, which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the "Miscellaneous Expense" area of the recall claim. Attachment II - Labor and Parts Information PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through the order processing channels as noted below: There are approximately 2,000 total vehicles involved in this recall. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. ORDER INFORMATION DOR/COR DOR/COR number 50168 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621). DEALER PRICE For latest prices, refer to: ^ DOES II Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall Side Airbag Sensor Replacements > Page 9646 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information DEMONSTRATION / DELIVERY HOLD - Certain 2000 Model Year Explorer/Mountaineer Side Airbag Crash Sensor Replacements Refer to the 2000 Explorer/Mountaineer workshop manual Group 5 Section 501-20B for side airbag crash sensor location and replacement instructions. NOTE: Removed parts must be mutilated and properly scrapped to prevent their use on another vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall Side Airbag Sensor Replacements > Page 9647 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 00S17 > Jun > 00 > Recall Side Airbag Sensor Replacements > Page 9648 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 9649 Impact Sensor: Specifications Side Crash Sensor 12 Nm Front Crash Sensor 10.2-13.8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 9652 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor Impact Sensor: Service and Repair Front External Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill and radiator opening cover. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 9655 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 9656 Impact Sensor: Service and Repair Side Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the B-pillar lower trim panel with scuff plates. NOTE: ^ Four door is shown, two door is similar. ^ The front seat has been removed for clarity. 3. Remove the side crash sensor. 1 Disconnect the side crash sensor electrical connector. 2 Remove the two retaining bolts. 3 Remove the side crash sensor with bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 9657 WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9663 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations > Page 9668 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Service and Repair Antenna Motor: Service and Repair REMOVAL NOTE: The antenna motor and the antenna cable is removed as an assembly. 1. Disconnect the battery ground cable. 2. Unsnap the radio antenna base cap. 3. Remove the radio antenna nut. 4. Remove the front fender apron. 1 Remove the screws. 2 Remove the bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Service and Repair > Page 9675 5. Remove lower antenna mounting screw. 6. Remove the RH cowl side trim panel. 7. Disconnect the antenna motor electrical connector. 8. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 9. Position the antenna lead in cable into the engine compartment. 1 Open the glove compartment door. 2 Release the tabs and lower the glove compartment to the full open position. 3 Release the antenna lead in cable wire locators. 4 Push the antenna lead in cable into the engine compartment. 10. Move the electric antenna motor forward and down to remove. 11. If necessary, to remove a broken section of plastic antenna drive cable, remove the cover and drive mechanism. 12. Locate and remove the broken piece of drive cable. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Service and Repair > Page 9676 NOTE: The antenna motor and antenna cable are installed as an assembly. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable Antenna Cable: Service and Repair Fixed Antenna Cable REMOVAL NOTE: The antenna base and the antenna cable are removed as an assembly. 1. Disconnect the battery ground cable. 2. Remove the radio antenna mast. ^ Slide the wind deflector up. ^ Remove the radio antenna mast by turning it counterclockwise. 3. Unsnap the radio antenna base cap. 4. Remove the radio antenna nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 9682 5. Remove the front fender apron. 1 Remove the screws. 2 Remove the bolts. 6. Remove the lower antenna mounting screw. 7. Remove the RH cowl side trim panel. 8. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 9. Position the antenna lead-in cable into the engine compartment. 1 Open the glove compartment door. 2 Release the tabs and lower the glove compartment to the full open position. 3 Release the antenna lead-in cable locators. 4 Push the antenna lead-in cable into the engine compartment. 10. Remove the antenna base and the antenna lead-in cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 9683 INSTALLATION NOTE: The antenna base and the antenna cable are installed as an assembly. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 9684 Antenna Cable: Service and Repair Power Antenna Cable REMOVAL NOTE: The power antenna cable and the antenna mast are removed as an assembly. 1. Unsnap the radio antenna base cap. 2. Remove the radio antenna nut. 3. Remove the antenna mast and cable. ^ Turn the ignition switch to the ACC position. ^ Turn the radio chassis ON/OFF switch to ON. ^ Firmly pull the antenna mast and cable out of the electric antenna motor. INSTALLATION NOTE: The power antenna cable and antenna mast are installed as an assembly. 1. Position the cable so the teeth are facing the front of the vehicle. NOTE: Check the end of the plastic antenna drive cable for a slight taper. If the drive cable is broken, a section of cable may be inside the electric antenna motor. Remove the broken cable. Refer to Antenna-Motor. 2. Insert the antenna. ^ Manually extend the antenna. ^ Insert the cable until resistance is felt. ^ Turn the cable slightly left and right to full engage the cable into the motor gear. 3. Have an assistant turn the ignition switch to ACC and turn the radio chassis ON/OFF switch from ON to OFF. 4. Apply light downward pressure to the antenna as the electric antenna motor starts retracting the cable. 5. Guide the antenna in as the motor winds the cable into the drive unit and retracts the antenna sections. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 9685 6. Install the radio antenna nut. 7. Install the radio antenna base cap. 8. Cycle the electric antenna motor several times to ensure the antenna is extending and retracting correctly. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9690 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9691 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9694 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9695 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9696 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9697 Alarm Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9698 Alarm Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9699 Alarm Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service Precautions Alarm System Transponder: Service Precautions CAUTION: Once the new module is installed, it is necessary to configure the module. For additional information, refer to Module Communication Network (Information Bus). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) Alarm System Transponder: Service and Repair Module-Passive Anti-Theft System (PATS) REMOVAL 1. Remove the passenger side air bag module; refer to Air Bags. 2. Remove the passive anti-theft system (PATS) module and bracket. 1 Remove the bolts. 2 Disconnect the electrical connector. 3. Release the retainer tabs and remove the PATS module from the bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9705 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to configure the module. For additional information, refer to Module Communication Network (Information Bus). NOTE: ^ Prior to starting the vehicle, check for PATS DTCs. Perform the appropriate pinpoint test. ^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory. Insert each key in the ignition and turn to RUN for automatic programming. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9706 Alarm System Transponder: Service and Repair Module-Passive Anti-Theft Transceiver REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9707 5. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 6. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. 7. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 8. Remove the transceiver assembly. 1 Remove the screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9708 2 Locate the rib on the steering column lock cylinder housing, and gently release the anti-theft transceiver over the rib. NOTE: Only apply pressure or leverage below the key cylinder lower rib. 3 Disconnect the electrical connector. NOTE: The steering wheel is shown removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 ml) or more to relearn the strategy. ^ No key replacement or re-initialization needs to occur with the removal or installation of a new PATS Transceiver. ^ The steering wheel is shown removed for clarity. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 9713 Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Service and Repair Ignition Key In Signal: Service and Repair Key-In-Ignition Warning Switch REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Pry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Service and Repair > Page 9717 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9723 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9724 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9725 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9726 Keyless Entry Key-Pad: Service Precautions CAUTION: Do not operate the radio chassis with a radio speaker disconnected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Removal And Installation Keyless Entry Key-Pad: Service and Repair Removal And Installation REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. CAUTION: Do not operate the radio chassis with a radio speaker disconnected. 3. Remove the screws and lift the radio speaker out to gain access to the electrical connector. 4. Disconnect the speaker wiring connector. 5. Disconnect the electrical connector. - Release harness pin-type retainers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Removal And Installation > Page 9729 6. Remove the keyless entry keypad and harness. 1 Remove the clip. 2 Remove the keyless entry keypad and harness. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Removal And Installation > Page 9730 Keyless Entry Key-Pad: Service and Repair Programming Programming your own personal entry code 1. Enter the factory-set code (keypad will illuminate when pressed). 2. Press the 1-2 control within five seconds of step 1. 3. Enter your personal five digit code. Enter each digit within five seconds of the previous one. NOTE: Do not use a code that includes five of the same number presets in sequential order. Thieves can easily figure out these types of codes. Your personal code does not replace the permanent code the the dealership gave you. You can use either code to unlock your vehicle. If a second personal code is entered, the module will erase the first personal code in favor of the new code. If you wish to erase your personal code, use the following instructions: Erasing your personal code 1. Enter the factory set code. 2. Press 1-2 within five seconds of step 1. 3. Press the 7-8 and 9-0 controls at the same time within five seconds of step 2. The system will now only respond to the factory-set code. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9736 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9737 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9739 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9740 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9741 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9742 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9743 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9744 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9745 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9746 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9747 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9748 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9749 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9750 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9751 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9752 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 9757 Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 9761 Security Lamp/Indicator: Description and Operation Once triggered, the anti-theft system flashes the low beam headlamps, the parking lamps, the THEFT indicator and sounds the horns. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 9766 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 9767 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 9768 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the jack storage panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the parking aid module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9777 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9778 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9784 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9785 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Distance Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Distance Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9791 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Distance Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9792 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Distance Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9798 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Distance Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9799 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9800 Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor 160 cm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9801 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9802 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams > Page 9806 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 2. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connector. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the instrument panel lower steering column cover. 1 Remove the screws. 2 Remove the instrument panel lower steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams > Page 9807 5. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 6. If equipped, position the column gearshift lever aside. 7. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the instrument cluster finish panel. ^ Disconnect the electrical connector. 8. Remove the parking aid switch. 1 Remove the screws. 2 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Service and Repair Parking Assist Warning Indicator: Service and Repair REMOVAL 1. Remove the LH quarter trim panel. 2. Remove the parking aid speaker. 1 Disconnect the electrical connector. 2 Remove the pin-type retainers. 3 Remove the parking aid speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9815 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9816 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9817 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9818 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9819 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9820 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9821 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9822 Driver/Vehicle Information Display: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9823 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9824 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9825 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9826 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9827 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9828 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9829 Driver/Vehicle Information Display: Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9830 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9831 Driver/Vehicle Information Display: Electrical Diagrams Diagram 69-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9832 Diagram 69-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description Driver/Vehicle Information Display: Description and Operation System Description The message center system consists of: - message center switch module - message center indicator Message Center Switch Module The message center switch module has seven switches and is located below the message center indicator in the center console. The message center switches are: ENGLISH/METRIC mode - fuel computer (FUEL) RANGE - STATUS - economy (ECON) - RESET - system check and warnings (SYSTEM CHECK) - OIL CHANGE RESET Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 9835 Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It Work ?) Display Dimming The dimming of the indicator display is controlled by the pulse width dimmer module. The voltage on Pin 2 controls the brightness of the message center display. When the exterior lamps are off, this voltage will be zero volts and the message center display will be at maximum brightness. When the exterior lamps are on, this voltage will be controlled by the pulse width dimmer module and will be between 2.5 volts and battery voltage. The message center display will be brighter as this voltage approaches battery voltage. If there is a warning on the message center display, the display will not dim to its lowest level. When the headlamps or parking lamps are OFF, the display of the message center indicator will be maximum brightness and the labels for the center five switches of the message center switch module will not be illuminated. When the head lamps or parking lamps are ON, the brightness of the display of the message center indicator and the labels for the center five switches of the message center switch module will be controlled by the pulse width dimmer module. English/Metric Mode The ENGLISH/METRIC switch controls the display mode for both the message center indicator and the electronic automatic temperature control. A press of the ENGLISH/METRIC switch will change both displays between english mode and metric mode. Vehicle Speed Signal The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4-wheel Anti-lock Brake System (4WABS) module. The 4WABS module sends the vehicle speed signal via circuit 679 (GY/BK) to all systems which require a vehicle speed signal input. Fuel Computer - Range The RANGE feature has two displays: the distance that can be traveled before refueling, and the distance that was traveled since the last trip odometer reset. The RANGE switch will change the message center indicator between the two displays. The RANGE (distance to empty) feature is calculated using the fuel flow signal from the Powertrain Control Module (PCM), the speed signal from the 4WABS module and the fuel level signal from the fuel level sender. The fuel flow and speed signals are used to calculate a Running Average Fuel Economy (RAFE), which is multiplied by the fuel remaining to give the range. RAFE is not the same number as the Average Fuel Economy displayed by the message center indicator. RAFE is based on the past driving history and can only be reset by disconnecting the battery. When the range decreases to 80 km (50 mile) to empty, the message center will display the LOW FUEL LEVEL warning. With a fuel tank full of fuel (160 ohm signal from fuel sender) and after a battery disconnect, the RANGE should be approximately 644 km (400 miles) to empty. The RANGE (trip odometer) feature is calculated using the speed signal from the 4WABS module. It can be reset to zero by pressing the reset switch while the trip odometer is displayed on the message center. Fuel Computer - Status The STATUS feature has two displays: Fuel-to-Empty and Fuel-Used. The STATUS switch will change the message center indicator between the two displays. The fuel-to-empty calculation is achieved using the fuel level signal from the fuel level sender. The fuel-used feature is calculated using the fuel flow signal from the PCM and can be reset to zero by pressing the RESET switch while the fuel-used feature is displayed on the message center. Fuel Computer - Economy The Economy (ECON) feature has two displays: average and instant. Depressing the ECON switch changes the message center indicator between both displays. The economy is calculated using the fuel flow signal from the powertrain control module and the speed signal from the 4WABS module. The average fuel economy feature can be reset by pressing the RESET switch while the average fuel economy feature is displayed on the message center indicator. System Check and Warnings Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 9836 The SYSTEM CHECK feature cycles the message center indicator through a status of each system being monitored. For each of the monitored systems, the message center indicator will indicate either an OK message or a warning message for two seconds. - At normal conclusion of the system check sequence, the message center indicator will display all active warnings or the last feature displayed before entering the SYSTEM CHECK mode. - System warnings alert the driver to possible concerns or malfunctions in the vehicle operating systems. - There are 7 warning messages which can be displayed for two seconds by the message center indicator to show the status of the monitored systems. - When a warning occurs, the warning message is displayed and a one-second tone sounds. The warning message will appear at a brighter level if the message center indicator is dimmed. - In the event of a multiple warning situation, the message center indicator will cycle the display to show all warnings by displaying each warning message for four seconds. - To display the operator selectable features of the message center indicator while a warning is displayed, the warning message may be removed from the message center indicator display by pressing the RESET switch. The message center indicator will display the last selected feature if there are no more warning messages. - This allows operation of all functions of the message center indicator after pressing the RESET switch and clearing the warning message. Warning messages which have been reset will either reappear on the display in 10 minutes from the reset or will not reappear until an ignition switch OFF-RUN cycle. If warning messages reappear it is a reminder that these warning conditions still exist. Warnings may be repeatedly reset. All warning messages will reappear after an entire SYSTEM CHECK sequence has been completed. Charging System Warning (CHECK CHARGING SYSTEM) This warning message is displayed when the electrical system is not maintaining correct voltage at the message center indicator. There will be a few seconds delay before the warning is displayed or removed. Engine Coolant Temperature Warning (CHECK ENGINE TEMP) This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts, at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Fuel Level Warning (LOW FUEL LEVEL) This warning message is displayed when there is approximately 80 km (50 mile) or less left before the vehicle runs out of fuel. Oil Level Warning (LOW OIL LEVEL) This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Oil Life Warning (CHANGE OIL SOON or OIL CHANGE REQUIRED) If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 9837 - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Washer Fluid Level Warning (LOW WASHER FLUID) This warning message is displayed when there is less than one quarter of the container of washer fluid remaining When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close, grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator. - When the washer fluid level is low, the input to the message center indicator will be open and the warning will be displayed. The message center indicator filters this input therefore, there will be a 20-second delay before the warning is displayed or removed. Warning Chime A short warning chime (0.1 second) is output with every message center switch press. A longer warning chime (1.0 second) is output when a new warning first appears on the message center indicator display. To activate the warning, the message center pulls the chime request output below one volt during the length of the tone. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 9838 Driver/Vehicle Information Display: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Remove the message center console. Grasp the front of the console and lift upward. 2. Disconnect the electrical connectors from the message center indicator. 3. Remove the screws retaining the message center indicator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 9841 Driver/Vehicle Information Display: Service and Repair Message Center Assembly Switch REMOVAL 1. Remove the message center indicator. Refer to Driver/Vehicle Information Display. 2. Disconnect the electrical connector. 3. Remove the message center switch module screws and remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 9842 73 Digital Multimeter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 9846 Garage Door Opener Transmitter: Service Precautions WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT USE THIS HOMELINK(R) WITH TRAVELNOTE TM TRANSMITTER WITH A DOOR OPENING SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED BEFORE APRIL 1, 1982. FOR MORE INFORMATION, CALL HOMELINK(R) WITH TRAVELNOTE TM CUSTOMER ASSISTANCE AT 1-800-355-3515. CAUTION: During this procedure, the system that you are programming will be made to operate. Make sure that people or objects are clear of the garage door or gate being programmed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 9847 Garage Door Opener Transmitter: Description and Operation The HomeLink(R) with TravelNote TM universal transmitter provides a convenient way to replace up to three hand-held transmitters with a single built-in device. The universal transmitter: ^ will operate garage doors, gates and home/office lighting and security systems. ^ will actually learn and transmit the radio frequency of up to three hand-held transmitters from any of the systems mentioned above. ^ is an integral part of the left sun visor assembly and is powered by the vehicle battery and charging system. In addition to the universal transmitter function, the HomeLink(R) with TravelNote TM also provides a convenient built-in recording device to safely store information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged universal transmitter ^ Damaged receiver 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9850 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9851 Garage Door Opener Transmitter: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. A1 - A2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 9852 Garage Door Opener Transmitter: Service and Repair WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT USE THIS HOMELINK(R) WITH TRAVELNOTE TM TRANSMITTER WITH A DOOR OPENING SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED BEFORE APRIL 1, 1982. FOR MORE INFORMATION, CALL HOMELINK(R) WITH TRAVELNOTE TM CUSTOMER ASSISTANCE AT 1-800-355-3515. 1. Verify the hand-held transmitter is operative. CAUTION: During this procedure, the system that you are programming will be made to operate. Make sure that people or objects are clear of the garage door or gate being programmed. 2. Prepare for programming the universal transmitter by erasing all three channels by holding down the two outside buttons until the red light begins to flash (20 - 30 seconds). Release both buttons. 3. Select one of the three universal transmitter channels to be programmed by pressing the desired button. 4. Hold the end of the hand-held transmitter 25 - 51 mm (1 - 2 in) from the front surface of the universal transmitter so that the red light can still be seen. 5. Use both hands to press the hand-held transmitter button and the desired button on the universal transmitter. Do not release either button. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after two seconds, which may not be long enough to program the universal transmitter. If programming this type of hand-held transmitter, continue to hold the button on the universal transmitter while re-pressing the hand-held transmitter button every two seconds (Canada only). 6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and then rapidly. Release both buttons when the rapid flashing begins. The universal transmitter has successfully learned the new frequency signal and can be used in place of the hand-held transmitter(s). 7. To operate, simply press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. NOTE: If the hand-held transmitter appears to program the universal transmitter but does not open the garage door, the garage door opener may have a "code protected" or "rolling code" feature. Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held transmitter to the universal transmitter. 2. Train the garage door opener receiver to recognize the universal transmitter. 1 Remove the cover panel from the garage door opener receiver. 2 Locate the training button on the garage door opener receiver. Location and color of the button may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual or call HomeLink(R) with TravelNote TM customer assistance at 1-800-355-3515. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 9853 3 Press the training button on the garage door opener receiver for 1 - 2 seconds. 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1 - 2 seconds). Release the button and re-press the button to confirm that the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Erasing Channels 1. To erase all three programmed channels, hold down the two outside buttons until the red light begins to flash (20 - 30 seconds). Release both buttons. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9862 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9863 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9864 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9865 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9866 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9867 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9868 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9869 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9870 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: Recalls Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Multifunction Electronic Control Modules: Customer Interest Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 9880 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9886 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9887 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9888 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9889 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9890 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9891 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9892 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9893 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9894 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: All Technical Service Bulletins Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Multifunction Electronic Control Modules: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 9903 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Multifunction Electronic Control Modules: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 9909 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9915 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9916 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9917 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9918 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9919 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9920 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9921 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9922 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 9923 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: All Technical Service Bulletins Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 9928 Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality Module 2.3-3.3 Nm Battery Ground Cable Screws 7-10 Nm GEM/CTM Screw 1.6-2.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 9929 Multifunction Electronic Control Modules: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 9930 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9933 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9934 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9935 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9936 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9937 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9938 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9939 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9940 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9941 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9942 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9943 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9944 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9945 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9946 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9947 Multifunction Electronic Control Modules: Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9948 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9949 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9950 Diagram 59-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9951 Diagram 59-3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9952 Diagram 59-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9953 Diagram 59-5 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9954 Diagram 59-6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 9955 Multifunction Electronic Control Modules: Description and Operation The multifunction modules consist of the following: ^ generic electronic module (GEM)/central timer module (CTM) ^ remote anti-theft personality (RAP) module The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated locks systems. The GEM/CTM controls the following features: ^ wiper/washer (front/rear) ^ warning chime ^ battery saver ^ illuminated entry and courtesy lamps ^ driver one touch down power window (GEM only) ^ accessory delay ^ 4 wheel drive (GEM only) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 9956 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic (GEM)/Central Timer (CTM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1 Remove the screw. 2 Disconnect the four connectors from the GEM/CTM. 3 Remove the GEM/CTM. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9959 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9960 Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft Personality (RAP) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static charges, damage may result. 2. Remove the LH rear quarter trim panel. 3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors. 4. Remove the two RAP module fasteners. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9961 5. Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications Amplifier: Specifications Radio Amplifier Bracket Bolt 10-14 Nm Radio Amplifier Bracket Nut 7-9 Nm Radio Amplifier Bracket Screw 7-10 Nm Radio Amplifier Mounting Screw 7-10 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 9974 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 9979 CD Changer: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the console compartment trim panel. ^ Remove the screws. ^ Remove the console compartment trim panel. 3. Remove the coin holder/tissue box holder. 4. Position the CD changer aside. 1 Remove the screws. 2 Position aside the CD changer. 5. Remove the CD changer. 1 Disconnect the connector. 2 Remove the screws. 3 Remove the CD changer brackets. 4 Remove the CD changer. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 9980 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9990 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9991 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9992 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9993 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9994 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9995 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9996 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10002 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10003 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10004 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10005 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10006 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10007 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10008 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 10009 Radio/Stereo Noise Filter: Specifications Intake Manifold Ground Strap Nut ...................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Radio Chassis Rear Support Nut ....................................................................................................................................................... 3.5-4 Nm (31-35 Lb-In) Rear Integrated Control Panel Screws .................................................................................................................................................. 2-3 Nm (17-26 Lb-In) Wiper Motor Stud Ground Strap Nut ................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Rear Radio Chassis Support .............................................................................................................................................................. 3.5-4 Nm (31-35 Lb-In) Battery Ground Cable Screw .............................................................................................................................................................. 7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt .............................................................................................................................................. 8.9-12.1 Nm (79-107 Lb-In) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 10010 Radio/Stereo Noise Filter: Description and Operation Radio Frequency Interference Suppression Equipment The radio suppression equipment reduces interference transmitted through the radio speakers by the engine ignition and electrical systems. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 10011 Radio/Stereo Noise Filter: Service and Repair GROUND STRAP REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and washer (A) attaching the ground strap (B) to the stud. 3. Remove the fastener from the rear of the intake manifold and ensure that the mounting surfaces of the studs are free of dirt and corrosion. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 10012 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair Remote Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel controls. 1 Carefully remove the steering wheel controls. 2 Disconnect the steering wheel controls. NOTE: The steering wheel is leather wrapped and should be protected when removing the steering wheel controls. INSTALLATION 1. Install the steering wheel controls. 1 Connect the steering wheel controls. 2 Install the steering wheel controls. 2. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair Remote Control: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the console compartment trim panel screws. 3. Remove the console compartment door hinge screw. 4. Remove the console rear panel screws at the top of the panel. 5. Remove the console rear panel screws at the cupholder. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Page 10019 6. Remove the rear integrated control panel screws. 7. Disconnect the floor/panel control arm at the control head. 8. Disconnect the rear blower motor control and rear radio controls electrical connectors. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Page 10020 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10029 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10030 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10031 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10032 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10033 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10034 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10035 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10041 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10042 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10043 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10044 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10045 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10046 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10047 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 10048 Speaker: Specifications Speaker Screws 2 Nm Subwoofer Screws 6.8-9.2 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 10049 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 10050 Speaker: Description and Operation The Explorer and Mountaineer are equipped with four premium radio speakers and an optional subwoofer. Rear radio speakers are mounted in the rear doors in four-door models or in the quarter panel in two-door models. Front radio speakers are mounted in the front doors. The optional MACH sound system replaces the front door premium radio speakers with audiophile radio speakers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers Speaker: Service and Repair Door Mounted Speakers REMOVAL 1. Remove the front door trim panels. 2. Remove the speakers. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the speakers. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers > Page 10053 Speaker: Service and Repair Rear (2 Door) Speaker REMOVAL 1. Remove the quarter trim panel. 2. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers > Page 10054 Speaker: Service and Repair Subwoofer Speaker REMOVAL 1. Remove the quarter trim panel. 2. Remove the subwoofer. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the subwoofer. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 10060 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 10064 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 10065 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 10068 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 10069 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 10070 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 10071 Alarm Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 10072 Alarm Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 10073 Alarm Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 10077 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10086 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10087 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10088 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10089 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10090 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10091 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10092 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10093 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > 00S04 > Apr > 00 > Recall - Multifunction Switch/Harness Replacement > Page 10094 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: Recalls Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Multifunction Electronic Control Modules: Customer Interest Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Customer Interest: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 10104 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10110 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10111 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10112 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10113 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10114 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10115 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10116 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10117 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10118 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: All Technical Service Bulletins Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Multifunction Electronic Control Modules: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 10127 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Multifunction Electronic Control Modules: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 10133 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement Technical Service Bulletin # 00S04 Date: 000401 Recall - Multifunction Switch/Harness Replacement 00S04 SAFETY RECALL Certain 1999 and 2000 Model Year Explorer and Mountaineer Automatic Four Wheel Drive (A4WD) Vehicles (Excluding Vehicles With Load Leveling and/or Memory Seat Option) - Jumper Harness Installation and Multifunction Switch Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10139 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10140 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee.Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10141 PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealership Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the repair. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim. PARTS RETENTION Follow the provision of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10142 Parts Ordering Information Parts will not be direct for this program. Order your part requirements through normal order processing channels as noted in the table. NOTE: DWE will not accept claims listing a separate Multifunction Switch part number. Dealers must use the kit part number listed above for completion of the program. The jumper harness must be installed to correct the safety concern addressed by this recall. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Exess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Bulletin 4000. Overview When performing this service procedure, you will: ^ Install a resistor jumper harness to correct a safety issue. ^ Replace the multifunction switch to correct a customer satisfaction concern. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. Resistor Jumper Harness Installation RESISTOR JUMPER HARNESS INSTALLATION 1. Record the radio stations and disconnect the battery ground cable. 2. Disconnect the ABS electrical connector located on the left-hand fender. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10143 3. Insert a tie strap through the locking tab on the power distribution box. See Figure 2. 4. Connect the resistor jumper harness to the ABS electrical connector and fasten the ABS connector with the tie strap to the power distribution box. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10144 See Figure 3. Multifunction Switch Replacement MULTIFUNCTION SWITCH REPLACEMENT 1. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 2. Remove the tilt wheel handle by turning the handle counterclockwise (it equipped). 3. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 4. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 4. 5. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 5. 6. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10145 7. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). 8. Install the upper and lower steering column shrouds. Tighten the screws 10 1 Nm (9 lb-in). 9. Install the tilt wheel handle (if equipped). 10. Install the ignition switch lock cylinder. 11. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10146 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > 00S04 > Apr > 00 > Recall Multifunction Switch/Harness Replacement > Page 10147 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Electronic Control Modules: > NHTSA00V072000 > Mar > 00 > Recall 00V072000: GEM Controlled Wiper Function Problem Multifunction Electronic Control Modules: All Technical Service Bulletins Recall 00V072000: GEM Controlled Wiper Function Problem Vehicle Description: Multi-purpose vehicles equipped with 4.0L engines and All-time 4-Wheel Drive (A4WD) powertrains. The generic electronic module (GEM) could experience a condition referred to as "lock-up" in which the GEM controlled electronic functions (e.g., front windshield wipers, interior lights, 4x4 system, etc.) could not be turned ON or, in some cases if the function is ON, could not be turned OFF. An inoperative windshield wiper system could affect driver visibility, increasing the risk of a crash. Dealers will install a resistor in the GEM circuit. Owner notification began April 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPLORER 1999 MERCURY TRUCK MOUNTAINEER 2000 FORD TRUCK EXPLORER 2000 MERCURY TRUCK MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 10152 Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality Module 2.3-3.3 Nm Battery Ground Cable Screws 7-10 Nm GEM/CTM Screw 1.6-2.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 10153 Multifunction Electronic Control Modules: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Technical Service Bulletins > Page 10154 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10157 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10158 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10159 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10160 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10161 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10162 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10163 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10164 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10165 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10166 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10167 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10168 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10169 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10170 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10171 Multifunction Electronic Control Modules: Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10172 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10173 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10174 Diagram 59-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10175 Diagram 59-3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10176 Diagram 59-4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10177 Diagram 59-5 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10178 Diagram 59-6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 10179 Multifunction Electronic Control Modules: Description and Operation The multifunction modules consist of the following: ^ generic electronic module (GEM)/central timer module (CTM) ^ remote anti-theft personality (RAP) module The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated locks systems. The GEM/CTM controls the following features: ^ wiper/washer (front/rear) ^ warning chime ^ battery saver ^ illuminated entry and courtesy lamps ^ driver one touch down power window (GEM only) ^ accessory delay ^ 4 wheel drive (GEM only) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 10180 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic (GEM)/Central Timer (CTM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1 Remove the screw. 2 Disconnect the four connectors from the GEM/CTM. 3 Remove the GEM/CTM. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 10183 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 10184 Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft Personality (RAP) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static charges, damage may result. 2. Remove the LH rear quarter trim panel. 3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors. 4. Remove the two RAP module fasteners. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 10185 5. Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10191 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10192 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10193 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10194 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10195 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10196 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10197 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10198 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10199 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10200 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10201 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10202 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10203 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10204 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 10205 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 10206 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 10207 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 10214 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 10215 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 10216 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the jack storage panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the parking aid module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 10222 Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 10227 Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 10236 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 10237 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 10243 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 10244 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 10245 Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor 160 cm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 10246 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 10247 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 10251 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 2. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connector. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the instrument panel lower steering column cover. 1 Remove the screws. 2 Remove the instrument panel lower steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 10252 5. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 6. If equipped, position the column gearshift lever aside. 7. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the instrument cluster finish panel. ^ Disconnect the electrical connector. 8. Remove the parking aid switch. 1 Remove the screws. 2 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair Remote Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel controls. 1 Carefully remove the steering wheel controls. 2 Disconnect the steering wheel controls. NOTE: The steering wheel is leather wrapped and should be protected when removing the steering wheel controls. INSTALLATION 1. Install the steering wheel controls. 1 Connect the steering wheel controls. 2 Install the steering wheel controls. 2. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 Diagram 95-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting system of the vehicle is operating properly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 3 (7.5 A) ^ CJB Fuse 7 (7.5 A) ^ CJB Fuse 30 (15 A) ^ Loose or corroded connections ^ Damaged circuity ^ Damaged relays ^ Failed bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10281 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10282 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. AA1 - AA2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10283 AB1 - AB2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10284 AC1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10285 AD1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10286 AE1 - AE2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10287 73 Digital Multimeter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10292 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10298 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10299 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10300 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10301 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10302 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10303 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10304 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10305 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10306 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10307 Diagram 95-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Technical Service Bulletins > Front Bumper Bracket - Replacement Tip Front Bumper Bracket: Technical Service Bulletins Front Bumper Bracket - Replacement Tip Article No. 99-20-3 10/04/99 BUMPER - FRONT BRACKET REPLACEMENT - SERVICE TIP FORD: 1995-2000 EXPLORER MERCURY: 1997-2000 MOUNTAINEER ISSUE During front end repair due to damage to the front end, the front frame horn or the entire frame is being replaced when only the front bumper bracket is damaged on some vehicles. A new Service Kit has been made available to replace front bumper brackets only. ACTION Replace front bumper brackets, if necessary, during front end repair. Refer to the procedure outlined on the Instruction Sheet in the Front Bumper Bracket Service kit. NOTE THIS KIT IS FOR FRONT BUMPER BRACKET REPLACEMENT ONLY. IT IS DESIGNED FOR UNDAMAGED FRONT FRAME RAILS. PART NUMBER PART NAME F57Z-17N775-AA Front Bumper Bracket Kit - RH (1995-1998) F57Z-17N775-BA Front Bumper Bracket Kit - LH (1995-1998) XL2Z-17N775-AA Front Bumper Bracket Kit - RH (1999-2000) XL2Z-17N775-BA Front Bumper Bracket Kit - LH (1999-2000) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 111000, 305000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair BUMPER COVER - EXPLORER Removal 1. Remove the front bumper. 2. Remove the bumper cover pin-type retainers. 3. Remove the six fasteners, one pin-type retainer and the air deflector. 4. Remove the bumper cover. 1. Remove the 12 screws. 2. Remove the bumper cover. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information > Service and Repair Rear Bumper Bracket: Service and Repair BUMPER BRACKET - REAR Removal 1. Remove the rear bumper (17906). 2. Remove the rear bumper isolator and bracket (17787). 1. Remove the nuts and bolts. 2. Remove the isolators and brackets. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair PANEL-COWL TOP VENT Removal 1. Disconnect the LH windshield washer hose from inside the engine compartment. 2. Remove the wiper arms. 1. Slide the clip to clear the wiper arm drive mechanism. 2. Pull the wiper arm from the wiper arm drive mechanism. 3. Remove the cowl top vent panel-to-cowl screw. 4. Remove the LH cowl top vent panel by pulling up on the LH cowl top vent panel to disengage the clips. 5. Remove the RH cowl top vent panel by pulling up on the RH cowl top vent panel to disengage the clips and disconnect the right washer hose. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 10326 1. To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Remove the watershield. 3. Remove the outside door handle. 1 Disconnect the front door latch to door handle rod. 2 Drill out the two rivets and remove the outside door handle. NOTE: The front door window glass must be completely up. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the rivets. NOTE: Front door shown, rear door similar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 10334 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Disconnect the inside door handle from the door. 1 Remove the screws. 2 Disconnect the inside door handle. 3. Disconnect the rod from the inside door handle. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft Front Door Hinge: Adjustments Hinge Adjustment - Front Door, Fore and Aft HINGE ADJUSTMENT - FRONT DOOR, FORE AND AFT NOTE: Check the rear door hinge adjustment before adjusting the front door hinge. 1. Remove the cowl side trim panel. 2. Position the electrical connector mounting bracket aside. 1. Remove the pin-type retainer. 2. Position the electrical connector mounting bracket aside. 3. Mark the position of the front door hinges to use as a reference point. 4. NOTE: Position the front door to gain access to the bolts. Loosen the two front door hinge to body bolts and nuts just enough to permit movement of the door. 5. Adjust the front door alignment to specification. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft > Page 10342 6. Tighten the front door hinge to body bolts. 7. Position the electrical connector mounting bracket. 1. Position the electrical connector mounting bracket. 2. Install the pin-type retainer. 8. Install the cowl side trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft > Page 10343 Front Door Hinge: Adjustments Hinge Adjustment - Front Door, Horizontal and Verticle HINGE ADJUSTMENT - FRONT DOOR, HORIZONTAL AND VERTICLE 1. Mark the position of the front door hinges to use as a reference point. 2. Loosen the front door hinge to front door bolts just enough to permit movement of the door. 3. Adjust the front door alignment to specification. 4. Tighten the front door hinge to front door bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications Front Door Latch: Specifications Door Latch Screws 4-8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 10347 Door Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 10348 Door Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 10349 Front Door Latch: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Disconnect the battery ground cable. 2. If removing the front door latch, remove the door lock cylinder; refer to Lock Cylinder-Door. 3. Remove the door trim panel. 4. Remove the door latch remote control. 1 Remove the screws. 2 Disconnect the door latch remote control link from the door latch remote control. 3 Remove the door latch remote control. 5. Disconnect the door latch actuating rod from the door latch. 6. Remove the rear glass run channel. 1 Remove the bolt. 2 Remove the rear glass run channel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 10350 7. Remove the door latch. 1 Remove the screws. 2 Disconnect the door latch from the power door lock actuator. 3 Remove the door latch. 8. Disconnect the door latch push button rod from the door latch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. - Connect the remote control rod, door latch push button rod and lock cylinder rod to the front door latch before installing the new latch. - When the battery is disconnected or reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 10351 The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair TRIM PANEL - FRONT DOOR Removal NOTE: High series shown, low series similar. - The window must be completely down to remove the front door trim panel. 1. On high series front door trim panel, disconnect the battery ground cable (14301). 2. Remove the screws. 3. Remove the inside door handle cup (22634). 4. On low series front door trim panel, remove the screw and the window regulator handle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 10355 5. Start in a lower corner and work around the panel and separate the front door trim panel (23942) from the front door (20124) to disengage the pin-type retainers. 6. Lift the front door trim panel to disengage the top lip from the weatherstrip. 7. Position the front door trim panel aside. 8. Separate the power window switch finish panel from the door trim panel. - Release the locking tabs. 9. If equipped, remove the courtesy lamp bulb from the lens and remove the front door trim panel. Installation 1. NOTE: When the battery (10653) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. NOTE: Lower the window glass to access the two rivets. 4. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the front door. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 10359 INSTALLATION 1. Position the front door window glass. NOTE: Slide the glass through the outboard side of the front door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the front door trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications Front Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 10363 Front Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 10364 Front Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 10365 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 10366 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 10367 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 10368 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications Front Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 10372 Front Door Window Regulator: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 10373 Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS Motor and Window Regulator - Front Door REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 10374 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 10375 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 10376 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 10377 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Remove the watershield. 3. Remove the outside door handle. 1 Disconnect the front door latch to door handle rod. 2 Drill out the two rivets and remove the outside door handle. NOTE: The front door window glass must be completely up. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the rivets. NOTE: Front door shown, rear door similar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Disconnect the inside door handle from the door. 1 Remove the screws. 2 Disconnect the inside door handle. 3. Disconnect the rod from the inside door handle. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Hinge Adjustment - Door, Rear Rear Door Hinge: Adjustments Hinge Adjustment - Door, Rear HINGE ADJUSTMENT - DOOR, REAR 1. Remove the front seat safety belt retractor. 2. Mark the position of the rear door hinges to use as a reference point. 3. Loosen the rear door hinge to body nuts just enough to permit movement of the door. 4. Adjust the rear door alignment to specification. 5. Tighten the rear door hinge to body nuts. 6. Check the front door hinge adjustment. 7. Install the front seat safety belt retractor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Hinge Adjustment - Door, Rear > Page 10390 Rear Door Hinge: Adjustments Hinge Adjustment - Rear Door, Horizontal and Vertical HINGE ADJUSTMENT - REAR DOOR, HORIZONTAL AND VERTICAL 1. Mark the position of the rear door hinge to use as a reference. 2. Loosen the rear door hinge to rear door bolts just enough to permit movement of the door. 3. Adjust the rear door alignment to specification. 4. Tighten the rear door hinge to rear door bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications Rear Door Latch: Specifications Door Latch Screws 4-8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 10394 Door Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 10395 Rear Door Latch: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Disconnect the battery ground cable. 2. If removing the front door latch, remove the door lock cylinder; refer to Lock Cylinder-Door. 3. Remove the door trim panel. 4. Remove the door latch remote control. 1 Remove the screws. 2 Disconnect the door latch remote control link from the door latch remote control. 3 Remove the door latch remote control. 5. Disconnect the door latch actuating rod from the door latch. 6. Remove the rear glass run channel. 1 Remove the bolt. 2 Remove the rear glass run channel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 10396 7. Remove the door latch. 1 Remove the screws. 2 Disconnect the door latch from the power door lock actuator. 3 Remove the door latch. 8. Disconnect the door latch push button rod from the door latch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. - Connect the remote control rod, door latch push button rod and lock cylinder rod to the front door latch before installing the new latch. - When the battery is disconnected or reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 10397 The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair TRIM PANEL - REAR DOOR Removal NOTE: High series shown, low series similar. - The window glass must be completely down to remove the rear door trim panel. 1. Remove the screws. 2. Remove the inside door handle cup. 3. On low series rear door trim panel, remove the window regulator handle. - Remove the screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 10401 4. Start in a lower corner and work around the panel and separate the rear door trim panel from the rear door to disengage the pin-type retainers. 5. Remove the rear door trim panel by lifting to disengage the top lip from the weatherstrip. 6. Turn the rear door trim panel over. 7. Disconnect the power window switch electrical connector. 1. Remove the screws. 2. Disconnect the electrical connector. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. 4. Remove the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 10405 1. Position the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the rear door trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications Rear Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 10409 Rear Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 10410 Rear Door Window Motor: Service and Repair REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Disconnect the battery ground cable. 3. Remove the rear door trim panel. 4. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Remove the power window motor. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the power window motor. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 10411 1. To install, reverse the removal procedure. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 10412 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 10416 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the rear door trim panel. 2. Disconnect the inside rear door handle from the rear door. 1 Remove the screws. 2 Disconnect the inside rear door handle. 3. Disconnect the rod from the inside rear door handle. 4. Remove the speaker. 1 Remove the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 10417 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Raise and support the rear door window glass to the full up position. 7. Disconnect the battery ground cable. 8. If equipped, disconnect the power window electrical connector. 9. Drill out the window regulator rivets. 10. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 10418 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 10419 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications Hood Latch: Specifications Hood Latch Bolts 10.5-13.5 Nm Hood Latch Control Handle Screws 2-4 Nm Hood Latch Release Handle Screws 2.7-3.7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 10424 Hood Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 10425 Hood Latch: Adjustments 1. Verify the hood alignment. 2. Remove the radiator grille sight shield. 1 Remove the bolts. 2 Remove the rivets. 3 Remove the radiator grille sight shield. 3. Align the hood latch. 1 Loosen the hood latch bolts enough to allow for movement of the hood latch. 2 Align the hood latch with the hood latch striker. 4. Tighten the hood latch bolts. 5. Verify the hood latch striker is fully engaging the hood latch. - Repeat the procedure as necessary. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 10426 Hood Latch: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the radiator grille sight shield. 1 Remove the bolts. 2 Remove the rivets. 3 Remove the radiator grille sight shield. 3. Remove the hood latch. 1 Remove the bolts. 2 Disconnect the hood latch cable from the hood latch. 3 Remove the hood latch. NOTE: Mark the hood latch position prior to removal of the bolts. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 10427 1. To install, reverse the removal procedure. - Adjust the hood latch; refer to Latch-Hood, Adjustment. See: Adjustments Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations Hood Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations > Page 10431 Hood Latch Release Cable: Service and Repair REMOVAL NOTE: The hood latch control handle and cable are replaced as an assembly. 1. Remove the hood latch. For additional information, refer to Hood Latch. 2. Unclip the hood latch control handle and cable retainer from the inner fender splash shield. 3. Position the hood latch control handle and cable aside. 1 Remove the two screws. 2 Position the hood latch control handle and cable aside. 4. Remove the hood latch control handle and cable. 1 Remove the hood latch control and cable grommet from the dash panel. 2 Remove the hood latch control handle and cable. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations > Page 10432 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 10438 OASIS CODES: 201000, 201200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Disconnect the two rear window defogger electrical connectors (one on each side). 3. Disconnect the two liftgate cylinders (one on each side). 4. Release the upper liftgate trim panel clips to gain access to liftgate window glass access plugs. 5. Remove the liftgate glass hinge access plugs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 10443 6. Remove the liftgate window glass. 1 Remove the two liftgate window glass to window hinge nuts. 2 Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Liftgate Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 10447 Power Trunk / Liftgate Lock Actuator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 5. Disconnect the liftgate handle rod. 1 Open the clip. 2 Disconnect the liftgate handle rod. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 10448 6. Disconnect the lock cylinder rod. 1 Open the clip. 2 Disconnect the lock cylinder rod. 7. Remove the liftgate latch remote control bolt. 8. Disconnect the liftgate lock actuator electrical connector. 9. Remove the liftgate lock actuator nuts. 10. Move the liftgate latch remote control to the LH opening and remove the liftgate lock actuator. INSTALLATION 1. Connect and position the liftgate lock actuator. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 10449 2. Install the liftgate lock actuator nuts. 3. Connect the liftgate lock actuator electrical connector. 4. Position the liftgate latch remote control. 5. Loosely install the liftgate latch remote control bolt. 6. Install the liftgate window latch. 1 Position the liftgate window latch. 2 Install the nuts. 3 Connect the electrical connector. NOTE: Manually close the liftgate window latch to set the latch control rod length. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 10450 7. Connect the liftgate window latch actuating rod. 1 Position the liftgate window latch actuating rod. 2 Close the clip. 8. Tighten the liftgate latch remote control bolt. 9. Connect the lock cylinder rod. 1 Position the lock cylinder rod. 2 Close the clip. NOTE: Be sure the bell crank of the liftgate latch remote control is in the unlocked position (upward) for proper lock cylinder rod length. 10. Connect the liftgate handle rod. 1 Position the liftgate handle rod. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 10451 2 Close the clip. NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 11. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not pre loading the liftgate latch. They should be clipped in a relaxed state with no slack. 12. Install the vent panel. 1 Position the vent panel. 2 Install the pin-type retainers. 13. Adjust the liftgate window latch. For additional information, refer to Liftgate Latch, Adjustment. See: Trunk / Liftgate Latch/Adjustments 14. Install the liftgate watershield. 15. Install the liftgate trim panel. 16. Connect the battery ground cable. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations Liftgate Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations > Page 10455 Trunk / Liftgate Handle: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the outside liftgate handle actuating rod. 1 Open the clip. 2 Disconnect the outside liftgate handle actuating rod. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations > Page 10456 5. Remove the license plate lamp shield 1 Remove the screws. 2 Remove the license plate lamp shield. 6. Remove the outside liftgate handle. 1 Drill out the rivets. 2 Remove the outside liftgate handle. INSTALLATION 1. To install, reverse the removal procedure. Use Heavy-Duty Riveter to install the rivets. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations > Page 10457 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair TRIM PANEL - LIFTGATE DOOR Special Service Tool(s) Special Service Tool(s) Removal 1. Remove the (A) liftgate handle to liftgate screws and the (B) liftgate handle. 2. Remove the liftgate trim panel screw access plug. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Page 10461 3. Remove the screw. 4. Remove the liftgate door trim panel. 1. Use Windshield and Molding/Trim Removal Kit to remove the liftgate door trim panel from the liftgate window opening. 2. Push the liftgate door trim panel toward the top of the liftgate and remove the liftgate trim panel. Installation 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications Trunk / Liftgate Latch: Specifications Liftgate Latch Bolt 9-14 Nm Liftgate Latch Remote Control 11-13 Nm Liftgate Window Latch Nuts 12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications > Page 10465 Liftgate Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications > Page 10466 Trunk / Liftgate Latch: Adjustments 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Close the liftgate window glass. 4. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 5. Loosen the liftgate window latch nuts. 6. Adjust the liftgate window latch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications > Page 10467 - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. 7. Tighten the liftgate window latch nuts. 8. Connect the liftgate window latch activating rod. 1 Connect the liftgate window latch actuating rod. 2 Lock the clip. 9. Verify the liftgate window glass flushness. 10. Install the liftgate watershield. 11. Install, the liftgate trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Disconnect the liftgate latch release rod from the liftgate latch remote control. 1 Open the clip. 2 Disconnect the liftgate latch release rod. 4. Remove the liftgate latch. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the liftgate latch and the liftgate release rod. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10470 1. To install, reverse the removal procedure. NOTE: If replacement of the liftgate latch release rods necessary, be sure to match the color coded rods for proper installation. - Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. - Position the liftgate latch release rod by pushing outboard to remove the slack. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10471 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control REMOVAL NOTE: If equipped with power locks, perform steps one and eight. 1. Remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate window latch. For additional information, refer to Liftgate Latch. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 5. Disconnect the liftgate handle rod. 1 Open the clip. 2 Disconnect the liftgate handle rod. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10472 6. Disconnect the lock cylinder rod. 1 Open the clip. 2 Disconnect the lock cylinder rod. 7. Remove the liftgate latch remote control bolt. 8. Remove the liftgate latch remote control from the liftgate. INSTALLATION NOTE: If equipped with power locks, perform steps one and two. 1. Install the latch remote control and (if equipped) the push button rod into the liftgate. 2. Install the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 3. Loosely install the liftgate latch remote control bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10473 4. Install the liftgate window latch. 1 Position the liftgate window latch. 2 Install the nuts. 3 Connect the electrical connector. NOTE: Manually close the liftgate window latch to set the latch control rod length. 5. Connect the liftgate window latch actuating rod. 1 Position the liftgate window latch actuating rod. 2 Close the clip. 6. Tighten the liftgate latch remote control bolt. 7. Connect the lock cylinder rod. 1 Position the lock cylinder rod. 2 Close the clip. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10474 8. Connect the liftgate handle rod. 1 Position the liftgate handle rod. 2 Close the clip. NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 9. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not preloading the liftgate latch remote control. They should be clipped in a relaxed state with no slack. 10. Install the vent panel. 1 Position the vent panel. 2 Install the pin-type retainers. 11. Adjust the liftgate window latch. For additional information, refer to Liftgate Window Latch, Adjustment. See: Adjustments Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10475 12. Install the liftgate watershield. 13. Install the liftgate trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10476 Trunk / Liftgate Latch: Service and Repair Liftgate window Latch REMOVAL 1. Open the liftgate window glass. 2. Remove the liftgate trim panel. 3. Remove the liftgate watershield. 4. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 5. Disconnect the electrical connector and remove the nuts. NOTE: Mark the position of the liftgate window latch prior to removing the nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 10477 6. Remove the liftgate window latch. INSTALLATION 1. To install, reverse the removal procedure. Before installing the liftgate trim panel, adjust the liftgate window latch; refer to Liftgate Window Latch, Adjustment. See: Adjustments NOTE: Manually close the liftgate window latch to set the latch control rod length. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10482 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10483 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10484 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10485 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10486 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 10487 Trunk / Liftgate Lock Cylinder: Specifications Liftgate Lock Cylinder Nuts 6-7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 10488 Liftgate Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 10489 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. If equipped, remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate latch remote control. For additional information, refer to Liftgate Latch. 3. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Manually close the liftgate window latch to set the latch control rod length. - Make sure the liftgate window latch actuating rod is not preloading the liftgate window latch. It should be clipped in a relaxed state with no slack. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 10493 Trunk / Liftgate Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 10494 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair PANEL-COWL TOP VENT Removal 1. Disconnect the LH windshield washer hose from inside the engine compartment. 2. Remove the wiper arms. 1. Slide the clip to clear the wiper arm drive mechanism. 2. Pull the wiper arm from the wiper arm drive mechanism. 3. Remove the cowl top vent panel-to-cowl screw. 4. Remove the LH cowl top vent panel by pulling up on the LH cowl top vent panel to disengage the clips. 5. Remove the RH cowl top vent panel by pulling up on the RH cowl top vent panel to disengage the clips and disconnect the right washer hose. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 10499 1. To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair Front Fender: Service and Repair FENDER - FRONT Removal 1. Remove the grille opening panel reinforcement. 2. Remove the front bumper (17757). 3. Remove the front panel of the rocker panel trim or, if equipped, the running board(s). 4. Remove the front wheel and tire assembly. 5. Remove the front fender apron (16054). 1. Remove the screws. 2. Remove the bolts. 6. Remove the lower fender to rocker panel bolts and spacers. 7. NOTE: The front door must be open to gain access to the fender bolt. Remove the fender bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page 10504 8. Remove the fender to front fender radiator support brace bolt. 9. If removing the RH front fender, position the speed control servo (9C735) aside. 1. Remove the bolt. 2. Position the speed control servo aside. 10. If removing the RH front fender, remove the antenna. 11. Remove the front fender (16005). 1. Remove the top fender to inner fender bolts. 2. Remove the front fender. Installation 1. Install the front fender. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page 10505 1. Install the front fender. 2. Install the top fender to inner fender bolts. 2. If installing the RH front fender, install the antenna. 3. If installing the RH front fender, install the speed control servo bracket. 1. Position the servo bracket. 2. Install the bolt. 4. Install the fender to front fender radiator support brace bolt. 5. NOTE: The front door must be open to gain access to the bolt. Install the top fender to inner fender bolt. 6. Install the fender to rocker panel bolts and spacers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page 10506 7. Install the front fender apron. 1. Install the front fender to front fender apron screws. 2. Install the top fender to inner fender bolts. 8. Install the front wheel and tire assembly. 9. Install the front panel of the rocker panel trim or, if equipped, the running board(s). 10. Install the front bumper. 11. Install the grille opening panel reinforcement. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation FRAME AND BODY MOUNTING Frame And Body Mounting Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 10511 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 10512 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 10513 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 10514 The frame (5005) consists of two steel channel rails, a rear crossmember, four additional support crossmembers and a front crossmember. The rails and crossmembers are not replaced separately. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE Removal NOTE: Explorer shown; Mountaineer similar. 1. Raise and support the hood (16612). 2. Remove the front upper radiator upper sight shield (8C291). 1. Remove the bolts. 2. Remove the pin type retainers. 3. Remove the radiator upper sight shield. 3. Remove the parking lamps. 4. Remove the radiator grille (8200). 1. Remove the screws. 2. Release the clips. 3. Remove the radiator grille. Installation NOTE: Explorer shown; Mountaineer similar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 10518 1. NOTE: Insert the locating tabs before installing the radiator grille screws. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Base Series Floor Console Rear Screw 2-3 Nm Base Series Floor Console Front Screws 3-4 Nm Upper Series Floor Console Bolts 9 Nm Upper Series Floor Console Electrical Connector Bolt 4.0-5.5 Nm Upper Series Front Floor Console Bolts 3.4-4.6 Nm Console Compartment Trim Panel Screw 2-3 Nm Console Glove Compartment Door Hinge Screw 2-3 Nm Console Rear Panel Screw 1.2-1.8 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 10523 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 10524 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series Console: Service and Repair Floor Console, Upper Series REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front floor console tray. - If equipped with message center, disconnect the three connectors. 3. Disconnect the floor console electrical connector. 1 Remove the bolt. 2 Disconnect the electrical connector. 4. Remove the front floor console bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 10527 5. Remove the center cupholder panel. 6. Remove the center floor console bolts. 7. Remove the floor console. NOTE: The console must be moved rearward to disengage the rear mounting bracket. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 10528 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 10529 Console: Service and Repair Floor Console, Base Series REMOVAL NOTE: The base floor console is shown; floor console with removable storage bin is similar. 1. Remove the front seat center armrest. 1 Remove the two covers. 2 Remove the four bolts. 3 Remove the armrest. 2. Remove the utility tray beverage holder. 3. Remove the floor console. 1 Remove the screws. 2 Remove the floor console. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 10530 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 10531 Console: Service and Repair Overhead Console REMOVAL 1. Disconnect the battery ground cable. 2. If equipped, open the garage door remote cover. 3. If equipped, remove the screws. 4. Remove the overhead console. 5. Disconnect the two electrical connectors (three connectors on moonroof equipped vehicles). INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10537 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10538 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10539 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10540 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10541 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10542 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures REMOVAL 1. Disconnect the battery ground cable. 2. Remove the quarter trim panel. 3. If equipped, remove the overhead console. 4. Remove the interior lamps. 5. Remove the sun visors. 1 Remove the six screws. 2 Remove the sun visors. If equipped, disconnect the electrical connectors. 6. Remove the sun visor brackets. 1 Remove the two screws. 2 Remove the sun visor brackets. 7. Remove the assist handle bolt covers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 10547 8. Remove the assist handles. 1 Remove the bolts. 2 Remove the assist handles. 9. Remove the headliner pin-type retainers. 10. Remove the six remaining pin-type retainers. 11. Remove the headliner. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 10548 Headliner: Removal and Replacement HEADLINER Removal 1. Disconnect the battery ground cable (14301). 2. Remove the quarter trim panel (31012). 3. If equipped, remove the overhead console. 4. Remove the interior lamps. 5. Remove the sun visors. 1. Remove the six screws. 2. Remove the sun visors. If equipped, disconnect the electrical connectors. 6. Remove the sun visor brackets. 1. Remove the two screws. 2. Remove the sun visor brackets. 7. Remove the assist handle bolt covers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 10549 8. Remove the assist handles. 1. Remove the bolts. 2. Remove the assist handles. 9. Remove the headliner pin-type retainers. 10. Remove the six remaining pin-type retainers. 11. Remove the headliner. Installation 1. NOTE: When the battery (10653) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the sun visor. - Position the sun visor as necessary. - Remove the sun visor screws. 3. Lower the sun visor and disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures A-Pillar Trim Panel Special Service Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the windshield side garnish moulding. 2. Remove the front door scuff plate. 1 Starting at one end and working along the front door scuff plate, use Windshield and Molding/Trim Removal Kit to remove the front door scuff plate. 2 Remove the front door scuff plate from the B-pillar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10557 3. Remove the (A) screw and the (B) coat hook. 4. Open the front safety belt guide bolt cover. 5. Using special tool, remove the front safety belt guide bolt. 6. Use Safety Belt Bolt Bit to remove the front safety belt anchor bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10558 7. Remove the B-pillar trim panel. 1 Remove the pin-type retainer. 2 Feed the safety belt webbing through the opening. 3 Remove the B-pillar trim panel. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10559 1. To install, reverse the removal procedure. Cowl Side Trim Panel Windshield and Molding/Trim Removal Kit Or Equivalent Special Service Tool(s) REMOVAL NOTE: 4-door shown, 2-door similar. 1. Remove the front door scuff plate. 1 Starting at one end and working along the front door scuff plate, use Windshield and Molding/Trim Removal Kit to remove the front door scuff plate. 2 Remove the front door scuff plate from the B-pillar. 2. Remove the cowl side trim panel by pulling outward to disengage the pin-type retainers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10560 INSTALLATION 1. To install, reverse the removal procedure. Liftgate Trim Panel Windshield and Molding/Trim Removal Kit Or Equivalent SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the (A) liftgate handle to liftgate screws and the (B) liftgate handle. 2. Remove the liftgate trim panel screw access plug. 3. Remove the screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10561 4. Remove the liftgate door trim panel. 1 Use Windshield and Molding/Trim Removal Kit to remove the liftgate door trim panel from the liftgate window opening. 2 Push the liftgate door trim panel toward the top of the liftgate and remove the liftgate trim panel. INSTALLATION 1. To install, reverse the removal procedure. Four Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10562 Special Service Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL 1. If equipped, remove the retractable cargo cover. 2. Remove the liftgate scuff plate. 1 Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim Removal Kit to remove the scuff plate. 2 Remove the liftgate scuff plate. 3. If equipped, remove the rear power lock switch assembly. - Disconnect the electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10563 4. Remove the B-pillar trim panel. 5. Remove the three rear quarter trim panel screws. - Position the carpet aside to gain access to the screws. 6. Remove the rear safety belt anchor nut. 7. Open the rear safety belt guide bolt cover. 8. Using the special tool, remove the rear safety belt guide bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10564 9. Remove the quarter trim panel. 1 Remove the pin-type retainers. 2 Feed the safety belt webbing through the opening in the quarter trim panel. 3 Remove the quarter trim panel. INSTALLATION 1. Install the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Position the quarter trim panel. 3 Install the pin-type retainers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10565 2. Using the special tool, install the rear safety belt guide bolt. 3. Close the rear safety belt guide bolt cover. 4. Install the rear safety belt anchor nut. 5. Install the three rear quarter trim panel screws. 6. Install the B-pillar trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10566 7. Install the liftgate scuff plate. 1 Position the liftgate scuff plate. 2 Start at either end and work along the liftgate scuff plate, pushing it into the floor panel. 8. If equipped, install the retractable cargo cover. Two Door Special Service Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10567 1. Remove the windshield side garnish moulding. 2. Remove the front door scuff plate. 3. Remove the front safety belt guide bolt cover. 4. Using the special tool, remove the front safety belt guide bolt. 5. Using the special tool, remove the front safety belt anchor bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10568 6. If equipped, remove the retractable cargo cover. 7. Remove the liftgate scuff plate. 1 Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim Removal Kit to remove the scuff plate. 2 Remove the liftgate scuff plate. 8. Fold the rear seat into the load floor position. 9. Using the special tool, remove the rear safety belt guide bolt. - Position the rear safety belt guide cover aside. 10. Using the special tool, remove the rear safety belt anchor bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10569 11. Remove the two rear quarter window latch screws. 12. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. 13. Remove the quarter trim panel front screw. - Position the carpet aside to gain access to the screw. 14. Remove the three quarter trim panel rear screws. - Position the carpet aside to gain access to the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10570 15. If equipped, remove the rear power lock switch assembly. - Disconnect the electrical connector. 16. Remove the quarter trim panel. 1 Remove the eight pin-type retainers. 2 Feed the safety belt webbing through the opening in the quarter trim panel. 3 Remove the quarter trim panel. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10571 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10572 Trim Panel: Removal and Replacement Trim Panel - B-Pillar TRIM PANEL - B-PILLAR Special Service Tool(s) Special Service Tool(s) Removal 1. Remove the windshield side garnish moulding (03598). 2. Remove the front door scuff plate (13208). 1. Starting at one end and working along the front door scuff plate, use Windshield and Molding/Trim Removal Kit to remove the front door scuff plate. 2. Remove the front door scuff plate from the B-pillar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10573 3. Remove the (A) screw and the (B) coat hook. 4. Open the front safety belt guide bolt cover. 5. Using special tool, remove the front safety belt guide bolt. 6. Use Safety Belt Bolt Bit to remove the front safety belt anchor bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10574 7. Remove the B-pillar trim panel. 1. Remove the pin-type retainer. 2. Feed the safety belt webbing through the opening. 3. Remove the B-pillar trim panel. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10575 1. To install, reverse the removal procedure. Trim Panel - Cowl Side TRIM PANEL - COWL SIDE Special Service Tool(s) Special Service Tool(s) Removal NOTE: 4-door shown, 2-door similar. 1. Remove the front door scuff plate (13208). 1. Starting at one end and working along the front door scuff plate, use Windshield and Molding/Trim Removal Kit to remove the front door scuff plate. 2. Remove the front door scuff plate from the B-pillar. 2. Remove the cowl side trim panel (02345) by pulling outward to disengage the pin-type retainers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10576 Installation 1. To install, reverse the removal procedure. Trim Panel - Quarter, Four Door TRIM PANEL - QUARTER, FOUR DOOR Special Service Tool(s) Special Service Tool(s) Removal 1. If equipped, remove the retractable cargo cover. 2. Remove the liftgate scuff plate (13144). 1. Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim Removal Kit to remove the scuff plate. 2. Remove the liftgate scuff plate. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10577 3. If equipped, remove the rear power lock switch assembly. - Disconnect the electrical connector. 4. Remove the B-pillar trim panel. 5. Remove the three rear quarter trim panel screws. - Position the carpet aside to gain access to the screws. 6. Remove the rear safety belt anchor nut. 7. Open the rear safety belt guide bolt cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10578 8. Using the special tool, remove the rear safety belt guide bolt. 9. Remove the quarter trim panel (31012). 1. Remove the pin-type retainers. 2. Feed the safety belt webbing through the opening in the quarter trim panel. 3. Remove the quarter trim panel. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10579 1. Install the quarter trim panel. 1. Feed the safety belt webbing through the opening in the quarter trim panel. 2. Position the quarter trim panel. 3. Install the pin-type retainers. 2. Using the special tool, install the rear safety belt guide bolt. 3. Close the rear safety belt guide bolt cover Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10580 4. Install the rear safety belt anchor nut. 5. Install the three rear quarter trim panel screws. 6. Install the B-pillar trim panel. 7. Install the liftgate scuff plate. 1. Position the liftgate scuff plate. 2. Start at either end and work along the liftgate scuff plate, pushing it into the floor panel. 8. If equipped, install the retractable cargo cover. Trim Panel - Quarter, Two Door TRIM PANEL - QUARTER, TWO DOOR Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10581 Special Service Tool(s) Special Service Tool(s) Removal 1. Remove the windshield side garnish moulding (03598). 2. Remove the front door scuff plate. 3. Remove the front safety belt guide bolt cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10582 4. Using the special tool, remove the front safety belt guide bolt. 5. Using the special tool, remove the front safety belt anchor bolt. 6. If equipped, remove the retractable cargo cover. 7. Remove the liftgate scuff plate (13144). 1. Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim Removal Kit to remove the scuff plate. 2. Remove the liftgate scuff plate. 8. Fold the rear seat into the load floor position. 9. Using the special tool, remove the rear safety belt guide bolt. - Position the rear safety belt guide cover aside. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10583 10. Using the special tool, remove the rear safety belt anchor bolt. 11. Remove the two rear quarter window latch screws. 12. Remove the coat hook. 1. Remove the screw. 2. Remove the coat hook. 13. Remove the quarter trim panel front screw. - Position the carpet aside to gain access to the screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10584 14. Remove the three quarter trim panel rear screws. - Position the carpet aside to gain access to the screws. 15. If equipped, remove the rear power lock switch assembly. - Disconnect the electrical connector. 16. Remove the quarter trim panel. 1. Remove the eight pin-type retainers. 2. Feed the safety belt webbing through the opening in the quarter trim panel. 3. Remove the quarter trim panel. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 10585 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10592 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10593 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10594 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10595 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10596 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 10597 Door Lock Cylinder: Service and Repair REMOVAL NOTE: - When a lock cylinder is replaced, both door lock cylinders, liftgate lock cylinders and ignition lock cylinder should be replaced as a set. This will eliminate carrying an extra key which will fit only one lock. If a key is to be replaced, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the front door trim panel. 2. Close the window. 3. Remove the watershield. 4. Disconnect the front door latch control cylinder rod from the door lock cylinder lever. 5. Slide the (A) door lock cylinder retainer away from the (B) lock cylinder and remove the cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10603 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10604 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 10605 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 10606 Keyless Entry Key-Pad: Service Precautions CAUTION: Do not operate the radio chassis with a radio speaker disconnected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Removal And Installation Keyless Entry Key-Pad: Service and Repair Removal And Installation REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. CAUTION: Do not operate the radio chassis with a radio speaker disconnected. 3. Remove the screws and lift the radio speaker out to gain access to the electrical connector. 4. Disconnect the speaker wiring connector. 5. Disconnect the electrical connector. - Release harness pin-type retainers. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Removal And Installation > Page 10609 6. Remove the keyless entry keypad and harness. 1 Remove the clip. 2 Remove the keyless entry keypad and harness. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Removal And Installation > Page 10610 Keyless Entry Key-Pad: Service and Repair Programming Programming your own personal entry code 1. Enter the factory-set code (keypad will illuminate when pressed). 2. Press the 1-2 control within five seconds of step 1. 3. Enter your personal five digit code. Enter each digit within five seconds of the previous one. NOTE: Do not use a code that includes five of the same number presets in sequential order. Thieves can easily figure out these types of codes. Your personal code does not replace the permanent code the the dealership gave you. You can use either code to unlock your vehicle. If a second personal code is entered, the module will erase the first personal code in favor of the new code. If you wish to erase your personal code, use the following instructions: Erasing your personal code 1. Enter the factory set code. 2. Press 1-2 within five seconds of step 1. 3. Press the 7-8 and 9-0 controls at the same time within five seconds of step 2. The system will now only respond to the factory-set code. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10616 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10617 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10618 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10619 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10620 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10621 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10622 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10623 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10624 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10625 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10626 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10627 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10628 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10629 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 10630 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 10631 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 10632 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Door Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Actuator Power Door Lock Actuator: Service and Repair Front Door Actuator Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the front door trim panel. 2. Remove the watershield 3. Remove the power door lock actuator. 1 Disconnect the electrical connector. 2 Drill out the rivet. 3 Disconnect the actuator rod. 4 Remove the actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the actuator rivet. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Actuator > Page 10639 Power Door Lock Actuator: Service and Repair Rear Door Actuator Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door watershield. 3. Remove the power door lock actuator. 1 Disconnect the electrical connector. 2 Drill out the rivet. 3 Disconnect the actuator rod. 4 Remove the actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the actuator rivet. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Page 10640 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 10644 Remote Anti-Theft Personality (RAP) Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 10645 Remote Anti-Theft Personality (RAP) Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 10646 Remote Anti-Theft Personality (RAP) Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 10650 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 10651 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models Power Door Lock Relay: Testing and Inspection Two Door Models Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 10654 Power Door Lock Relay: Testing and Inspection Four Door Models Driver Door Unlock Relay Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 10655 Door Lock/Unlock Relays Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch 4 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 10660 Power Door Lock Switch: Diagrams Power Door Lock Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 10663 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 10664 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 10665 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10670 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10671 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10672 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10673 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10674 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 10675 Trunk / Liftgate Lock Cylinder: Specifications Liftgate Lock Cylinder Nuts 6-7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 10676 Liftgate Latch Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 10677 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. If equipped, remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate latch remote control. For additional information, refer to Liftgate Latch. 3. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Manually close the liftgate window latch to set the latch control rod length. - Make sure the liftgate window latch actuating rod is not preloading the liftgate window latch. It should be clipped in a relaxed state with no slack. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10686 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10687 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10688 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Premature Clearcoat Cracking Service Tips Paint: Technical Service Bulletins Paint - Premature Clearcoat Cracking Service Tips Article No. 02-17-1 PAINT-PREMATURE CLEARCOAT CRACKING-SERVICE TIPS FORD: 1999-2002 EXPLORER 2000-2002 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: 1999-2002 MOUNTAINEER ISSUE Some vehicles may exhibit crowsfoot or premature star cracking primarily on the hood, but could also be on other panels. This is due to high paint film build and acrylic melamine paint technology. ACTION Read this TSB in its entirety BEFORE beginning any repairs. Inspect and repair as outlined in following Service Procedures. SERVICE PROCEDURE 1999-2002 Vehicles-Dark Colors (Code LL Blue, Code UA Black, and Code SU Green only) NOTE READ THIS REPAIR PROCEDURE COMPLETELY. SUBJECT VEHICLES HAVE PAINT THICKNESS ABOVE 5.5 MILS. 1. Check paint film thickness on affected panels. NOTE IF PLASTIC MEDIA BLASTING IS BEING USED, PROCEED TO STEP 4. NOTE TECHNICIAN PERFORMING THE SANDING OPERATION SHOULD WEAR AN APPROVED RESPIRATOR WITH HIGH EFFICIENCY PARTICULATE FILTERS (HEPA). TECHNICIANS SHOULD USE A DUAL ACTION SANDER WITH VACUUM COLLECTION EQUIPMENT. THE VACUUM EQUIPMENT MUST BE EQUIPPED WITH A HEPA FILTER ON THE AIR EXHAUST. OPERATORS ARE CAUTIONED TO FOLLOW MANUFACTURERS GUIDELINES FOR MAINTENANCE OR REPLACEMENT OF THESE FILTERS. 2. Remove all clearcoat and basecoat by sanding down to the E-coat primer with 80 grit-sanding discs on a Dual Action vacuum sander. The E-coat color is Green. 3. Blow off the panel with compressed air to remove loose dust and debris. 4. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. Keep wiping until the surface is completely dry. 5. Mask off all necessary panels. Tack off the surface. 6. Mix and apply Ford Approved epoxy or self-etching primer to all bare metal areas on the panel. 7. Mix and apply 2.0 mils minimum of Ford Approved primer surfacer following the manufacturers label recommendations and bake at 140°F (60° C) panel temperature per manufacturers recommended baking time. 8. Block sand the affected panels with 600 grit sand paper. 9. Blow off the area with compressed air to remove loose dust and debris. 10. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. NOTE KEEP WIPING UNTIL THE SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY RESULT CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. 11. Mix and apply Ford Approved basecoat material following the manufacturers label recommendations and flash time. 12. Mix and apply 2.0 mils minimum of Ford Approved clearcoat and bake at 140°F (60°C) panel temperature per manufacturers recommended baking time. 13. Demask the vehicle as necessary. WARNING TO SAFEGUARD OUR ENVIRONMENT, PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (VOC) OR EXCESS MATERIALS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Premature Clearcoat Cracking Service Tips > Page 10694 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes IDENTIFICATION CODES The Vehicle Identification Number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The VIN number is also found on the Vehicle Certification (VC) label. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10697 VEHICLE CERTIFICATION LABEL CODES The Vehicle Certification (VC) label contains the manufacturer name, the month and year of manufacture, the certification statement, and the VIN. It also includes Gross Vehicle Weight Ratings (GVWR). The following lists the exterior paint codes: Primary body color codes B2 - Harvest Gold - B4 - Autumn Brown - FL - Medium-Toreador Red - FS - Spruce Green - LD - Medium Wedgewood Blue - LL - Deep Wedgewood Blue - SU - Amazon Green - UA - Ebony - WF - White Pearl, tri-coat (St. Louis build only) - YZ - Oxford White Lower two-tone exterior paint codes: RC - Medium Platinum - BA - Medium Prairie Tan (Mountaineer Appearance Package) - JL - Dark Toreador Red - LD - Medium Wedgewood Blue - ST - Estate Green Tape Stripe Codes Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10698 - L - Light Prairie Tan (Limited) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10699 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10715 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10716 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10717 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10718 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10719 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 10720 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 10721 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 10722 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 10726 Remote Anti-Theft Personality (RAP) Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 10727 Remote Anti-Theft Personality (RAP) Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Remote Anti-Theft Personality (RAP) Module <--> [Power Door Lock Control Module] > Component Information > Locations > Page 10728 Remote Anti-Theft Personality (RAP) Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 10732 4 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 10733 2 Door W/Electronics Group Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models Power Door Lock Relay: Testing and Inspection Two Door Models Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 10736 Power Door Lock Relay: Testing and Inspection Four Door Models Driver Door Unlock Relay Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 10737 Door Lock/Unlock Relays Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams Power Seat Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 10741 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information Power Seat Control Module: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information > Page 10744 Power Seat Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 10745 Power Seat Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Remove the Driver Seat Module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. INSTALLATION CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 10746 1. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left > Page 10751 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 10752 Seat Heater Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Disconnect the heated seat module electrical connector. 4. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 10753 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Install the heated seat module. 2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications Sunroof / Moonroof Motor: Specifications Roof Opening Panel Motor Bolts 5 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 10759 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 10760 Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Remove the overhead console. For additional information, refer to Interior Trim. 2. Remove the motor. 1 Remove the bolts. 2 Disconnect the electrical connector. NOTE: Make sure that the roof opening panel motor is in the closed position before removal. INSTALLATION 1. Connect the roof opening panel motor electrical connector. NOTE: The roof opening panel should be in the closed position. 2. Position the overhead console and connect the electrical connectors. 3. With the motor still removed, bump the switch one time only towards the close or vent open position. 4. Position the roof opening panel motor and install the bolts. 5. Install the overhead console. For additional information, refer to Interior Trim. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Air Deflector Sunroof / Moonroof Windguard: Service and Repair Air Deflector REMOVAL 1. Open the roof opening panel to the fully retracted position. 2. Release the two air deflector arms. 3. Remove the air deflector. 1 Detach the two air deflector retainer clips from the U-frame. 2 Remove the air deflector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Air Deflector > Page 10768 Sunroof / Moonroof Windguard: Service and Repair Roof Opening Panel Shield REMOVAL 1. Remove the roof opening panel. 2. Remove the water channel. 1 Remove the screws. 2 Remove the water channel. 3. Slide the roof opening panel shield forward halfway. 4. Disengage the roof opening panel shield spring loaded guide feet. 1 Push the roof opening panel shield toward one side of the vehicle. 2 Lift the front portion of the roof opening panel shield upward to disengage the spring loaded guide feet. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Air Deflector > Page 10769 5. Slide the roof opening panel shield forward and release the rear guide feet. INSTALLATION 6. To install, reverse the removal procedure. NOTE: When installing the water channel, make sure that the water channel is seated on the locking clips. The LH water channel screw must be installed first. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair Sunroof / Moonroof Drain: Service and Repair REMOVAL 1. Remove the headliner. 2. From underneath the vehicle, securely attach a new drain hose to the lower end of the old drain hose. 3. Disconnect the drain hose from the roof opening panel assembly. 4. Pull the old drain hose through the body of the vehicle and connect the new hose to the roof opening panel. NOTE: Make sure that the hoses are not kinked. INSTALLATION 1. Install the headliner. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair REMOVAL 1. Remove the headliner. 2. Disconnect the roof opening panel motor electrical connector. 3. Remove the roof opening panel frame. 1 Disconnect the four drain hoses. 2 Remove the fourteen screws. 3 Remove the roof opening panel frame. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams Power Seat Control Module: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Page 10784 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information Power Seat Control Module: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information > Page 10787 Power Seat Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Page 10788 Power Seat Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Remove the Driver Seat Module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. INSTALLATION CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Page 10789 1. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left Power Seat Motor: Diagrams Left W/O Memory Seats Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left > Page 10794 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left > Page 10795 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left > Page 10800 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 10803 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch Power Seat Switch: Testing and Inspection Seat Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch > Page 10806 Power Seat Switch: Testing and Inspection Seat Regulator Control Switch Remove the seat regulator control switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket Power Seat Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10809 5. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 6. Unhook the side shield from the seat latch. 7. If equipped, disconnect the heated seat switch electrical connector. 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10810 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10811 Power Seat Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10812 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10813 9. If equipped, disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10823 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10824 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10825 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10826 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10827 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10828 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10829 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10830 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10831 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10832 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10833 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10839 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10840 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10841 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10842 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10843 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10844 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10845 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10846 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10847 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10848 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 10849 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information Seat Cushion: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information > Page 10854 Seat Cushion: Vehicle Damage Warnings CAUTION: - The flex mat J-clips must be installed with the openings facing down or the seat cushion will be damaged. - Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. - Any time the seat cushion heating element is removed from the seat cushion foam, the foam must be replaced. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench Seat Cushion: Service and Repair 40% Portion of Rear 60/40 Split Bench DISASSEMBLY 1. Disassemble the rear 40 percent seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. 2. Remove the rear seat legs. 1. Remove the pivot bolts. 2. Remove the rear seat legs. 3. Unhook the seat cushion trim cover J-clips. 4. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10857 5. Remove the seat cushion flex mat. 1. Unhook the rear flex mat J-clip. 2. Unhook the front flex mat J-clip. 3. Remove the seat cushion flex mat. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mat. 1. Position the seat cushion flex mat. 2. Hook the front flex mat J-clip. 3. Hook the rear flex mat J-clip. CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion will be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat J-clip. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10858 3. Hook the seat cushion trim cover J-clips. 4. Install the rear seat riser pivot bolts. 1. Position the rear seat legs. 2. Install the rear seat riser pivot bolts. 5. Assemble the rear 40 percent seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10859 Seat Cushion: Service and Repair 60% Portion of Front 60/40 Split Bench DISASSEMBLY 1. Disassemble the seat. For additional information, refer to Seat-60% Portion of Front 60/40 Split Bench. 2. Unhook the seat cushion trim cover J-clips. 3. Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim cover. 5. Remove the seat cushion trim cover. Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. ASSEMBLY 1. To assemble, reverse the disassembly procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10860 Seat Cushion: Service and Repair 60% Portion of Rear 60/40 Split Bench DISASSEMBLY 1. Disassemble the 60 percent rear seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. 2. Remove the seat cushion legs. 1. Remove the pivot bolts. 2. Remove the seat cushion legs. 3. Remove the seat cushion frame from the seat cushion foam. 1. Unhook the seat cushion trim cover J-clips. 2. Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim cover. 5. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10861 6. Remove the seat cushion flex mats. 1. Unhook the rear flex mat J-clips. 2. Unhook the front flex mat J-clips. 3. Remove the seat cushion flex mats. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mats. 1. Position the seat cushion flex mats. 2. Hook the front flex mat J-clips. 3. Hook the rear flex mat J-clips. CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion foam will be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat clip. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10862 3. Install the seat cushion frame into the seat cushion foam. 1. Position the seat cushion frame. 2. Hook the seat cushion trim cover J-clips. 4. Install the seat cushion legs. 1. Position the seat cushion legs. 2. Install the rear seat riser pivot bolts. 5. Assemble the 60 percent rear seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10863 Seat Cushion: Service and Repair Front Bucket 6-Way Power, Except Limited DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - Before disconnecting the battery, raise the seat to the highest position, then move and tilt the seat to its most forward position. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the 6-way power front bucket seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except limited. NOTE : Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6Way Power, Except Limited, Disassembly and Assembly. 3. Disconnect the seat cushion trim cover J-clips. 4. If equipped, disconnect the seat cushion heating element electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10864 5. Remove the seat cushion frame from the seat cushion foam. 6. Invert the seat cushion trim cover. 7. Remove the swing rods. 1 Remove and discard the hog rings. 2 Remove the swing rods. 8. Remove the seat cushion trim cover. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 9. If equipped, and if necessary, remove the seat cushion heating element from the seat cushion foam. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10865 CAUTION: Any time the seat cushion heating element is removed from the seat cushion foam, the foam must be replaced. 10. Remove the wire harness from the scat cushion frame. ASSEMBLY 1. Install the wire harness. 2. If equipped, and if necessary, install the seat cushion heating element. 3. Position the seat cushion trim cover. NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the front seat back pad adjusting cable, backrest heating element electrical lead, and the side air bag wiring harness. Use the old seat cushion trim cover as a guide for the location of the hole. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10866 4. Install the seat cushion swing rods. 1 Position the swing rods. NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of the seat cushion foam. 2 Install the hog rings. 5. Invert the seat cushion trim cover. 6. Connect the seat cushion trim cover J-clips. 7. Assemble the 6-way power front bucket seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Disassembly and Assembly. 8. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Prove out the air bag system. For additional information, refer to Air Bag Systems. 10. Check the restraint system for proper operation. Limited DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10867 - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - Before disconnecting the battery, raise the seat to the highest position, then move and tilt the seat to its most forward position. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, Limited, Disassembly and Assembly. 3. Disconnect the seat backrest recliner actuator. 1 Remove the screws. 2 Disconnect the seat backrest recliner actuator. 4. If equipped, disconnect the seat cushion heating element electrical connector. 5. Remove the seat cushion frame from the seat cushion foam. 1 Unhook the seat cushion trim cover J-clips. 2 Remove the seat cushion frame from the seat cushion foam. 6. Invert the seat cushion trim cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10868 7. Remove and discard the hog rings. 1 Fold back the seat cushion trim cover to expose the hog rings. 2 Remove and discard the hog rings. NOTE: The hog rings along the front of the seat are shown, the hog rings along either side are similar. 8. If equipped, and if necessary, remove the seat cushion heating element from the seat cushion foam. CAUTION: Any time the seat cushion heating element is removed from the seat cushion foam, the foam must be replaced. NOTE: Sport bucket seat shown; Limited seat similar. 9. Disconnect the heated seat module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10869 10. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. 11. Remove the driver seat module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. 12. Disconnect the lumbar support adjusting pump electrical connector. 13. Remove the power seat wiring harness. 1 Disconnect the pin-type retainers. 2 Remove the power seat wiring harness. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10870 14. Remove the flexilator. 1 Remove the flexilator springs. 2 Remove the flexilator. 15. Remove the lumbar support adjusting pump. 1 Remove the bolt. 2 Remove the lumbar support adjusting pump. 16. Remove the seat backrest recliner roll pins and remove the seat backrest recliners. 17. Disconnect the seat backrest recliners from the seat backrest recliner actuator. 1 Disconnect the seat backrest recliner actuator cable housings from the seat backrest recliners. 2 Unhook the seat backrest recliner actuator cables from the seat backrest recliners. ASSEMBLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10871 1. Connect the seat backrest recliners to the seat backrest recliner actuator. 1 Hook the seat backrest recliner actuator cables to the seat backrest recliners. 2 Connect the seat backrest recliner actuator cable housings to the seat backrest recliners. 2. Install the seat backrest recliner roll pins. 3. Install the lumbar Support adjusting pump. 1 Position the lumbar support adjusting pump. 2 Install the bolt. 4. Install the flexilator. 1 Position the flexilator. 2 Install the flexilator springs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10872 5. Install the power seat wiring harness. 1 Position the power seat wiring harness. 2 Install the pin-type retainers. 6. Connect the lumbar support adjusting pump electrical connector. 7. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 8. Install the hog rings. 1 Fold back the seat cushion trim cover to the hog ring installation position. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10873 2 Install the hog rings. NOTE: The hog rings along the front of the seat are shown; the hog rings along either side are similar. 9. Invert the seat cushion trim cover. 10. Install the seat cushion frame. 1 Position the seat cushion frame. 2 Hook the seat cushion trim cover J-clips. 11. If equipped, connect the seat cushion heating element electrical connector. 12. Connect the seat backrest recliner actuator. 1 Connect the seat backrest recliner actuator. 2 Install the screws. Tighten until the screws are fully seated. 13. Assemble the seat. For additional information, refer to Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, Limited, Disassembly and Assembly. 14. Reactivate the supplemental restraint system. For additional information, refer to Section Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Prove out the air bag system. For additional information, refer to Air Bag Systems. 16. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10874 Manual DISASSEMBLY 1. Disassemble the manual front bucket seat. For additional information, refer to Seat-Front Bucket, Manual. 2. Disconnect the seat cushion trim cover J-clips. 3. Remove the seat cushion trim cover. - Disconnect the seat trim cover from the hook and loop strips. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 4. Remove the seat cushion. - Disconnect the front and rear J-clips. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10875 5. Remove the flexilator. 1. Remove the flexilator to frame springs. 2. Disengage the spring clip. 3. Disengage the flexilator hooks from the seat frame. 4. Remove the flexilator. ASSEMBLY 1. Install the flexilator. 1. Position the flexilator. 2. Install the flexilator hooks to the seat frame. 3. Hook the spring clip. 4. Install the flexilator to frame springs. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. 3. Connect the seat cushion trim cover J-clips. 4. Assemble the manual front bucket seat. For additional information, refer to Seat-Front Bucket, Manual. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10876 Seat Cushion: Service and Repair Rear 50/50 Split Bench DISASSEMBLY 1. Remove the pivot legs. 1. Remove the bolts. 2. Remove the pivot legs. 2. Remove the seat cushion trim cover. - Disconnect the pin-type retainers. 3. Remove the seat cushion foam from the seat cushion frame. ASSEMBLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 10877 1. To assemble, reverse the disassembly procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Left > Page 10882 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 10883 Seat Heater Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Disconnect the heated seat module electrical connector. 4. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 10884 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Install the heated seat module. 2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Left > Page 10889 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket Seat Heater Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10892 5. Release the side shield clips. 6. Disconnect the heated seat switch electrical connector. 7. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10893 Seat Heater Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10894 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10895 9. Disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual Seat Track: Service and Repair Front Manual REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket, Removal and Installation. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket. 3. Place the front seat upside-down on a clean workbench. 4. Remove the safety belt buckle slide bar. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle slide bar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 10900 5. Remove the seat track to seat cushion front bolts. 6. Remove the front seat track. 1 Remove the seat track to seat cushion rear bolts. 2 Remove the front seat track. INSTALLATION 1. Install the front seat track front bolts. 1 Position the front seat track. 2 Install the inboard bolt. 3 Install the outboard bolt. 2. Install the front seat track rear bolts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 10901 1 Install the inboard bolt. 2 Install the outboard bolt. 3. Install the safety belt buckle slide bar. 1 Position the safety belt buckle slide bar. 2 Install the nut. 3 Install the bolt. 4. Install the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 5. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Prove out the air bag system. For additional information, refer to Air Bag Systems. 7. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 10902 Seat Track: Service and Repair Limited and 6-Way Power REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: - LHD seats shown, RHD seat similar. - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Place the seat on a clean workbench. 4. Remove the safety belt buckle slide bar. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle slide bar. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 10903 5. Disconnect the seat track wiring hamess electrical connectors. - If equipped, disconnect the memory seat module electrical connectors. - Disconnect the seat track motor electrical connectors. 6. Remove the seat track. 1 Remove the bolts. 2 Remove the seat track. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When installing the power seat track, start at the corner with the round hole and work around the seat base in a horseshoe pattern. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 10904 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 10911 OASIS CODES: 201000, 201200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch 4 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 10916 Power Door Lock Switch: Diagrams Power Door Lock Switch Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 10919 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 10920 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 10921 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10925 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10926 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10927 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 10932 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 10935 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch Power Seat Switch: Testing and Inspection Seat Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch > Page 10938 Power Seat Switch: Testing and Inspection Seat Regulator Control Switch Remove the seat regulator control switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket Power Seat Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10941 5. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 6. Unhook the side shield from the seat latch. 7. If equipped, disconnect the heated seat switch electrical connector. 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10942 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10943 Power Seat Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10944 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 10945 9. If equipped, disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left > Page 10950 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket Seat Heater Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10953 5. Release the side shield clips. 6. Disconnect the heated seat switch electrical connector. 7. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10954 Seat Heater Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10955 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 10956 9. Disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 10966 Trunk / Liftgate Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 10967 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is installed: - Under the hood. - Above and below the instrument panel. - At the cowl side panels. - Over the front and rear tunnel. - Over the front and rear floor pans. - Inside the B, C, and D pillars. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair PANEL-COWL TOP VENT Removal 1. Disconnect the LH windshield washer hose from inside the engine compartment. 2. Remove the wiper arms. 1. Slide the clip to clear the wiper arm drive mechanism. 2. Pull the wiper arm from the wiper arm drive mechanism. 3. Remove the cowl top vent panel-to-cowl screw. 4. Remove the LH cowl top vent panel by pulling up on the LH cowl top vent panel to disengage the clips. 5. Remove the RH cowl top vent panel by pulling up on the RH cowl top vent panel to disengage the clips and disconnect the right washer hose. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 10976 1. To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10990 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10991 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10992 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10993 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10994 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10995 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10996 Attachment III - Technical Information Table of Contents Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10997 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10998 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10999 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11000 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11001 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11002 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11003 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11004 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11005 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11006 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11007 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11008 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11009 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11010 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11011 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11012 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11014 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11015 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11020 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11030 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11031 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11032 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11033 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11034 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11035 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11036 Attachment III - Technical Information Table of Contents Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11037 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11038 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11039 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11040 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11041 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11042 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11043 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11044 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11045 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11046 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11047 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11048 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11049 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11050 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11051 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11052 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11053 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11054 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11055 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11060 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 11061 Brake Switch (Cruise Control): Specifications Deactivator Switch 15-20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 11064 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 11065 Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 11066 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11075 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11076 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11077 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11078 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11079 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11080 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11081 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11082 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11083 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11084 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11085 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11086 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11087 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11088 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11089 Owner Letter Owner Letter not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair PANEL-COWL TOP VENT Removal 1. Disconnect the LH windshield washer hose from inside the engine compartment. 2. Remove the wiper arms. 1. Slide the clip to clear the wiper arm drive mechanism. 2. Pull the wiper arm from the wiper arm drive mechanism. 3. Remove the cowl top vent panel-to-cowl screw. 4. Remove the LH cowl top vent panel by pulling up on the LH cowl top vent panel to disengage the clips. 5. Remove the RH cowl top vent panel by pulling up on the RH cowl top vent panel to disengage the clips and disconnect the right washer hose. Installation Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > System Information > Service and Repair > Page 11092 1. To install, reverse the removal procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11102 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11103 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11104 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11105 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11106 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11107 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11108 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11109 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11110 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11111 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11112 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11113 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11114 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11115 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Switch: > 03-24-1 > Dec > 03 > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11116 Owner Letter Owner Letter not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > Customer Interest: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Air Bag Harness: Customer Interest Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Article No. 03-24-1 12/08/03 ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994 AND/OR B1998 FORD: 1999-2001 EXPLORER SPORT, EXPLORER MERCURY: 1999-2001 MOUNTAINEER This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage. ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998 stored in memory. This may be due to a high resistance or poor connections in the side air bag (SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles equipped with, or without, side air bags. ACTION To service, install an overlay harness which incorporates soldered terminals and tin wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation instructions and illustrations are included in the kit. SERVICE PROCEDURE FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z" 1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction sheet included in the kit. FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D" 1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet included in the kit. ^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB ^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC ^ 1999-2000 2DR Explorer XL2Z-14B455-BC ^ 2001 2DR Explorer 1L2Z-14B455-AC Reference section 501-20A of the appropriate model year Workshop Manual for additional information if needed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > Customer Interest: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 > Page 11124 Labor Operation Claiming Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-01-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B455 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Air Bag Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Article No. 03-24-1 12/08/03 ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994 AND/OR B1998 FORD: 1999-2001 EXPLORER SPORT, EXPLORER MERCURY: 1999-2001 MOUNTAINEER This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage. ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998 stored in memory. This may be due to a high resistance or poor connections in the side air bag (SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles equipped with, or without, side air bags. ACTION To service, install an overlay harness which incorporates soldered terminals and tin wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation instructions and illustrations are included in the kit. SERVICE PROCEDURE FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z" 1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction sheet included in the kit. FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D" 1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet included in the kit. ^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB ^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC ^ 1999-2000 2DR Explorer XL2Z-14B455-BC ^ 2001 2DR Explorer 1L2Z-14B455-AC Reference section 501-20A of the appropriate model year Workshop Manual for additional information if needed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 > Page 11130 Labor Operation Claiming Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-01-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B455 42 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11136 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11137 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11138 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11139 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11140 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11141 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11142 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11143 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11144 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11145 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11146 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11147 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11148 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11149 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 09S09 > Oct > 09 > Recall Cruise Control Deactivation Switch Overheating > Page 11150 Owner Letter Owner Letter not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Speed Control Servo Bracket Bolt 9-12 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11154 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11155 Cruise Control Servo: Service Precautions WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11156 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect the speed control servo electrical connector. 2. Remove the speed control actuator cable cap from the speed control servo. ^ Push the locking arm on the speed control actuator cable cap then rotate the cap counterclockwise. 3. Disconnect the speed control core wire end from the speed control servo pulley. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley. 4. Remove the speed control servo bracket bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11157 5. Remove the speed control servo. INSTALLATION 1. Install the speed control servo bracket bolt. 2. Insert the speed control cable slug into the speed control servo pulley slot. 1 Gently compress the speed control servo spring. 2 Insert the speed control cable slug into the speed control servo pulley slot. 3. Release the compressed spring while aligning the speed control actuator cable cap tabs with the slots in the speed control servo housing. WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. NOTE: Make sure the rubber seal is fully seated onto the speed control actuator cable cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11158 4. Rotate the speed control actuator cable cap until the locking arm engages. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications Cruise Control Servo Cable: Specifications Accelerator Control Splash Shield Bolt (4.0L [Push Rod], 5.0L) .......... 8-12 Nm ............ (71-106Lb-In) Accelerator Control Splash Shield Bolts (4.0L SOHC) ......................... 3.1-4.3 Nm ........ (2.5-3 Lb-Ft) Battery Ground Cable .......................................................................7-10 Nm ............ (62-89 Lb-In) Speed Control Actuator Cable Bolt .....................................................3.1-4.3 Nm ........ (27-38 Lb-In) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 11162 Cruise Control Servo Cable: Service Precautions WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 11163 Cruise Control Servo Cable: Adjustments REMOVAL 1. Remove the speed control actuator cable clip. 2. Adjust the speed control actuator cable. 1 Make sure the throttle body cam is in the closed position. 2 Pull on the speed control actuator cable to remove any slack. 3 Back off the speed control actuator cable one notch. NOTE ^ The speed control actuator cable must not be pulled tight for proper operation. ^ The throttle body cam will automatically spring set to the closed position. The throttle body cam must be in the closed position. INSTALLATION 1. Install the speed control actuator cable clip. 1 Hold the speed control actuator cable. 2 Insert the speed control actuator clip securely. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 11164 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolt. 2 Remove the splash shield. 2. Remove the speed control cable from the accelerator bracket. 3. Remove the speed control actuator cable cap from the speed control servo. ^ Push in the locking arm on the speed control actuator cable cap then rotate the cap counterclockwise. 4. Disconnect the speed control core wire end from the speed control servo pulley. 1 Depress the spring retainer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 11165 2 Slide the core wire end out of the speed control servo pulley. INSTALLATION 1. Insert the speed control cable slug into the speed control servo pulley slot. 1 Gently compress the speed control servo spring. 2 Insert the speed control cable slug into the speed control servo pulley slot. 2. Release the compressed spring while aligning the speed control actuator cable cap tabs with the slots in the speed control servo housing. WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. NOTE: Make sure the rubber seal is fully seated onto the speed control actuator cable cap. 3. Rotate the speed control actuator cable cap until the locking arm engages. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 11166 4. Snap the speed control actuator cable and the accelerator cable together in the clip and install the cables onto the accelerator cable bracket. 5. Position the accelerator control splash shield and install the bolt. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11180 Cruise Control Switch: Specifications Speed Control Actuator Switch Screws 6.5-7.5 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11181 Cruise Control Switch: Service Precautions CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11182 Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio Cruise Control Switch: Service and Repair Without Remote Audio REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switches. 1 Remove the screws. 2 Disconnect the electrical connector then remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio > Page 11185 Cruise Control Switch: Service and Repair With Remote Audio REMOVAL 1. Disconnect the battery ground cable. 2. Separate the speed control actuator switch out of the steering wheel. CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. 3. Remove the speed control actuator switch. 1 Disconnect the speed control actuator switch electrical connector. 2 Remove the speed control actuator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn its strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11199 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11201 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11202 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11203 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11204 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11205 Attachment III - Technical Information Table of Contents Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11206 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11207 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11208 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11209 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11210 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11211 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11212 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11213 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11214 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11215 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11216 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11217 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11218 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11219 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11220 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11221 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11222 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11223 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11224 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11229 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11239 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11240 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11241 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11242 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11243 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11244 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11245 Attachment III - Technical Information Table of Contents Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11246 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11247 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11248 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11249 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11250 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11251 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11252 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11253 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11254 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11255 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11256 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11257 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11258 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11259 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11260 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11261 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11262 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11263 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11264 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11269 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 11270 Brake Switch (Cruise Control): Specifications Deactivator Switch 15-20 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 11273 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 11274 Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 11275 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11284 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11285 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11286 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11287 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11288 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11289 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11290 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11291 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11292 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11293 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11294 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11295 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11296 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11297 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11298 Owner Letter Owner Letter not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11304 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11305 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11306 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11307 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11308 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11309 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11310 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11311 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11312 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11313 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11314 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11315 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11316 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11317 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 11318 Owner Letter Owner Letter not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Page 11319 Clutch Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11333 Cruise Control Switch: Specifications Speed Control Actuator Switch Screws 6.5-7.5 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11334 Cruise Control Switch: Service Precautions CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11335 Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio Cruise Control Switch: Service and Repair Without Remote Audio REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switches. 1 Remove the screws. 2 Disconnect the electrical connector then remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio > Page 11338 Cruise Control Switch: Service and Repair With Remote Audio REMOVAL 1. Disconnect the battery ground cable. 2. Separate the speed control actuator switch out of the steering wheel. CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. 3. Remove the speed control actuator switch. 1 Disconnect the speed control actuator switch electrical connector. 2 Remove the speed control actuator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn its strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 11343 ABS Light: Description and Operation The Antilock Brake System (ABS) uses the yellow ABS warning indicator to alert the driver of a malfunctions in the ABS. The yellow ABS warning indicator will come on to warn the driver that the ABS has been turned off due to a symptom that exists in the ABS. Normal power assist braking remains but wheels can lock during a panic stop while the yellow ABS warning indicator is illuminated. The diagnostic procedures must be followed step-by-step in order to correct the condition. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Conditioning Indicator Lamp > Component Information > Service and Repair Air Conditioning Indicator Lamp: Service and Repair Climate Control Bulb For additional information, refer to Heating and Air Conditioning. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 11355 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 11361 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11364 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11365 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11366 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11367 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11368 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11369 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11370 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11371 Audible Warning Device: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11372 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11373 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11374 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11375 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11376 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11377 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11378 Audible Warning Device: Electrical Diagrams Diagram 66-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11379 Diagram 66-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11380 Diagram 66-3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 11381 Audible Warning Device: Description and Operation A short warning chime (0.1 second) is output with every message center switch press. A longer warning chime (1.0 second) is output when a new warning first appears on the message center indicator display. To activate the warning, the message center pulls the chime request output below one volt during the length of the tone. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 11382 Audible Warning Device: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 11383 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11389 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11390 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11391 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11392 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11393 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 11403 Audible Warning Device Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 11404 Audible Warning Device Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 11405 Audible Warning Device Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 11409 Brake Warning Indicator: Description and Operation Brake System The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction or a parking brake that is not fully released. The brake fluid level switch is located in the brake fluid reservoir. The yellow brake warning indicator is used to indicate a malfunction or deactivation of the Anti-lock Brake System (ABS). It illuminates when triggered by the ABS control module and stays illuminated as long as the malfunction remains in the system. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster Charge Lamp/Indicator: Description and Operation Instrument Cluster The charge system warning indicator illuminates when there is no generator (GEN) output. When the ignition switch contacts are closed, battery current flows through the charge indicator and the parallel resistor (390 ohm) to the voltage indicator, and the indicator illuminates. When the generator builds up enough voltage to energize a circuit in the voltage regulator, the indicator goes out. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster > Page 11415 Charge Lamp/Indicator: Description and Operation Information and Message Center This warning message is displayed when the electrical system is not maintaining correct voltage at the message center indicator. There will be a few seconds delay before the warning is displayed or removed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations > Page 11419 Check Gauges Lamp: Description and Operation The CHECK GAGE indicator will illuminate if any of the following occur: - Engine oil pressure drops below approximately 42 kPa (6 psi). - Fuel level drops below approximately 4-8 L (1-2 gal). - Engine temperature exceeds approximately 121°C (250°F). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 Cigarette Lighter: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11433 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11434 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11435 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11436 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11437 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11438 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11439 Diagram 44-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 11443 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 11444 Compass: Service Precautions CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 11445 Compass: Description and Operation A compass and outside temperature display are contained in the overhead console. The compass and temperature display can be turned off and on by pressing the MODE switch in the overhead console. The vehicle heading is displayed as one of N, NE, E, SE, S, SW, W, and NW. Compass Accuracy Magnetic mounted devices like antennas and luggage racks should not be located on the front third of the vehicle roof. Placing these devices near the compass will cause inaccurate directional readings. If these devices must be used, accuracy may be improved by recalibrating the compass while the devices are installed on the vehicle. Driving near power lines, or driving in the area of large iron or steel structures can temporarily change the compass heading. If the compass remains inaccurate after driving near such objects, demagnetize the vehicle and recalibrate the compass. Most geographic areas (zones) have a magnetic north compass point that varies slightly from the northerly direction on maps. This variation is four degrees between the adjacent zones and will become noticeable as the vehicle crosses multiple zones. A correct zone setting eliminates the error. Refer to Compass Zone Adjustment. See: Adjustments/Compass Zone Adjustment Temperature, Outside Air The thermometer sensor is attached to the radiator frame behind the grille. The temperature can be displayed in centigrade or Fahrenheit by pressing the MODE switch. If the outside temperature falls below 3.3°C (38°F), the display will alternate from "ICE" to the outside temperature at a two second rate for one minute. The outside air temperature reading can be affected by engine heat when the vehicle is idling or has been off for less than two hours. The compass and thermometer will limit the increase of the displayed temperature to one degree per minute at very low speeds or immediately after the ignition is turned on. After two minutes at a sustained speed of at least 53 km/h (33 mph), effects of engine heat are minimal and the compass will display the current outside temperature reading. Temperature decreases are always updated immediately. If the outside air temperature sensor is short or open circuited, then the display will show 60°C (140°F) or -40°C (-40°F) respectively in place of temperature. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compass: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the compass and thermometer. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If inspection reveals an obvious concern(s) that can be readily identified, repair or replace as required. 4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11448 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11449 Compass: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. Pinpoint Test Notes NOTE: - Always set the zone, calibrate, and demagnetize a vehicle before replacing an inaccurate compass. - After replacing the compass, always set the zone and calibrate. Test A: Compass Is Inaccurate/Inoperative A1 - A2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11450 A3 - A4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11451 A5 - A6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11452 A7 - A8 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11453 A9 - A10 Test B: Outside Air Temperature Is Inaccurate/Inoperative Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11454 B1 - B2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11455 B3 - B4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11456 B5 - B6 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11457 Special Service Tool(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment Compass: Adjustments Compass Zone Adjustment 1. Determine the zone in which the vehicle is located. 2. Press and hold the MODE button until VAR appears on the display. Release the MODE button. 3. Momentarily press the MODE button to increment the zone by one. Set the zone according to the map. NOTE: After a few seconds, the compass will exit the VAR mode if the button is no longer pressed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 11460 Compass: Adjustments Calibration Adjustment 1. Start the vehicle. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. 2. Locate the electronic compass/temperature display on the overhead console, press and hold the MODE button until CAL appears in the display, then release the MODE button. NOTE: To exit CAL mode before performing a compass adjustment, turn the ignition switch to the OFF position. 3. Drive the vehicle slowly (less than 5 km/h [3 mph]) in complete circles until CAL disappears from the display. NOTE: If the CAL indicator does not turn off after the vehicle has been driven in a circle no more than five times, demagnetize the vehicle and repeat the procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 11461 Compass: Adjustments Vehicle Demagnetizing CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. Perform the Compass Zone Adjustment procedure. See: Compass Zone Adjustment 3. Perform the Compass Calibration Adjustment procedure. See: Calibration Adjustment Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 11462 Compass: Service and Repair REMOVAL 1. Remove the overhead console; refer to Interior Trim. 2. Remove the screws and disconnect the electrical connector. 3. Remove the compass/lamp bezel from the console housing. 1 Push the clip. 2 Remove the compass/lamp bezel from the console housing. 4. Remove the compass and thermometer. 1 Push the three locking tabs. 2 Remove the compass and thermometer. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 11463 Special Service Tool(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Locations > Page 11467 Cruise Control Indicator Lamp: Description and Operation The Speed Control Indicator (SPEED CONT) lamp will illuminate when the speed control is engaged. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11473 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11474 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11475 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11476 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11477 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11478 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Page 11482 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations > Page 11486 Door/Trunk Ajar Indicator/Lamp: Description and Operation The DOOR AJAR indicator illuminates when any of the vehicle doors are open. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 11490 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11495 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11496 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11497 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11498 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11499 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11500 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11501 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11502 Driver/Vehicle Information Display: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11503 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11504 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11505 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11506 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11507 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11508 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11509 Driver/Vehicle Information Display: Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11510 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11511 Driver/Vehicle Information Display: Electrical Diagrams Diagram 69-1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 11512 Diagram 69-2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description Driver/Vehicle Information Display: Description and Operation System Description The message center system consists of: - message center switch module - message center indicator Message Center Switch Module The message center switch module has seven switches and is located below the message center indicator in the center console. The message center switches are: ENGLISH/METRIC mode - fuel computer (FUEL) RANGE - STATUS - economy (ECON) - RESET - system check and warnings (SYSTEM CHECK) - OIL CHANGE RESET Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 11515 Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It Work ?) Display Dimming The dimming of the indicator display is controlled by the pulse width dimmer module. The voltage on Pin 2 controls the brightness of the message center display. When the exterior lamps are off, this voltage will be zero volts and the message center display will be at maximum brightness. When the exterior lamps are on, this voltage will be controlled by the pulse width dimmer module and will be between 2.5 volts and battery voltage. The message center display will be brighter as this voltage approaches battery voltage. If there is a warning on the message center display, the display will not dim to its lowest level. When the headlamps or parking lamps are OFF, the display of the message center indicator will be maximum brightness and the labels for the center five switches of the message center switch module will not be illuminated. When the head lamps or parking lamps are ON, the brightness of the display of the message center indicator and the labels for the center five switches of the message center switch module will be controlled by the pulse width dimmer module. English/Metric Mode The ENGLISH/METRIC switch controls the display mode for both the message center indicator and the electronic automatic temperature control. A press of the ENGLISH/METRIC switch will change both displays between english mode and metric mode. Vehicle Speed Signal The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4-wheel Anti-lock Brake System (4WABS) module. The 4WABS module sends the vehicle speed signal via circuit 679 (GY/BK) to all systems which require a vehicle speed signal input. Fuel Computer - Range The RANGE feature has two displays: the distance that can be traveled before refueling, and the distance that was traveled since the last trip odometer reset. The RANGE switch will change the message center indicator between the two displays. The RANGE (distance to empty) feature is calculated using the fuel flow signal from the Powertrain Control Module (PCM), the speed signal from the 4WABS module and the fuel level signal from the fuel level sender. The fuel flow and speed signals are used to calculate a Running Average Fuel Economy (RAFE), which is multiplied by the fuel remaining to give the range. RAFE is not the same number as the Average Fuel Economy displayed by the message center indicator. RAFE is based on the past driving history and can only be reset by disconnecting the battery. When the range decreases to 80 km (50 mile) to empty, the message center will display the LOW FUEL LEVEL warning. With a fuel tank full of fuel (160 ohm signal from fuel sender) and after a battery disconnect, the RANGE should be approximately 644 km (400 miles) to empty. The RANGE (trip odometer) feature is calculated using the speed signal from the 4WABS module. It can be reset to zero by pressing the reset switch while the trip odometer is displayed on the message center. Fuel Computer - Status The STATUS feature has two displays: Fuel-to-Empty and Fuel-Used. The STATUS switch will change the message center indicator between the two displays. The fuel-to-empty calculation is achieved using the fuel level signal from the fuel level sender. The fuel-used feature is calculated using the fuel flow signal from the PCM and can be reset to zero by pressing the RESET switch while the fuel-used feature is displayed on the message center. Fuel Computer - Economy The Economy (ECON) feature has two displays: average and instant. Depressing the ECON switch changes the message center indicator between both displays. The economy is calculated using the fuel flow signal from the powertrain control module and the speed signal from the 4WABS module. The average fuel economy feature can be reset by pressing the RESET switch while the average fuel economy feature is displayed on the message center indicator. System Check and Warnings Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 11516 The SYSTEM CHECK feature cycles the message center indicator through a status of each system being monitored. For each of the monitored systems, the message center indicator will indicate either an OK message or a warning message for two seconds. - At normal conclusion of the system check sequence, the message center indicator will display all active warnings or the last feature displayed before entering the SYSTEM CHECK mode. - System warnings alert the driver to possible concerns or malfunctions in the vehicle operating systems. - There are 7 warning messages which can be displayed for two seconds by the message center indicator to show the status of the monitored systems. - When a warning occurs, the warning message is displayed and a one-second tone sounds. The warning message will appear at a brighter level if the message center indicator is dimmed. - In the event of a multiple warning situation, the message center indicator will cycle the display to show all warnings by displaying each warning message for four seconds. - To display the operator selectable features of the message center indicator while a warning is displayed, the warning message may be removed from the message center indicator display by pressing the RESET switch. The message center indicator will display the last selected feature if there are no more warning messages. - This allows operation of all functions of the message center indicator after pressing the RESET switch and clearing the warning message. Warning messages which have been reset will either reappear on the display in 10 minutes from the reset or will not reappear until an ignition switch OFF-RUN cycle. If warning messages reappear it is a reminder that these warning conditions still exist. Warnings may be repeatedly reset. All warning messages will reappear after an entire SYSTEM CHECK sequence has been completed. Charging System Warning (CHECK CHARGING SYSTEM) This warning message is displayed when the electrical system is not maintaining correct voltage at the message center indicator. There will be a few seconds delay before the warning is displayed or removed. Engine Coolant Temperature Warning (CHECK ENGINE TEMP) This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts, at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Fuel Level Warning (LOW FUEL LEVEL) This warning message is displayed when there is approximately 80 km (50 mile) or less left before the vehicle runs out of fuel. Oil Level Warning (LOW OIL LEVEL) This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Oil Life Warning (CHANGE OIL SOON or OIL CHANGE REQUIRED) If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 11517 - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Washer Fluid Level Warning (LOW WASHER FLUID) This warning message is displayed when there is less than one quarter of the container of washer fluid remaining When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close, grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator. - When the washer fluid level is low, the input to the message center indicator will be open and the warning will be displayed. The message center indicator filters this input therefore, there will be a 20-second delay before the warning is displayed or removed. Warning Chime A short warning chime (0.1 second) is output with every message center switch press. A longer warning chime (1.0 second) is output when a new warning first appears on the message center indicator display. To activate the warning, the message center pulls the chime request output below one volt during the length of the tone. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 11518 Driver/Vehicle Information Display: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Remove the message center console. Grasp the front of the console and lift upward. 2. Disconnect the electrical connectors from the message center indicator. 3. Remove the screws retaining the message center indicator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 11521 Driver/Vehicle Information Display: Service and Repair Message Center Assembly Switch REMOVAL 1. Remove the message center indicator. Refer to Driver/Vehicle Information Display. 2. Disconnect the electrical connector. 3. Remove the message center switch module screws and remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 11522 73 Digital Multimeter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Description and Operation Fuel Gauge Module: Description and Operation NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Description and Operation > Page 11530 Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Description and Operation > Page 11531 Fuel Gauge Module: Service and Repair Service and Repair The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and must be replaced as a set. For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 11535 Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 11536 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11542 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11543 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11544 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11545 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11546 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11547 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Description and Operation Instrument Panel Circuit Board: Description and Operation The instrument cluster printed circuit is a flexible circuit that supplies power and ground to the instrument cluster indicators and gauges. It is constructed of copper foil bonded to a polyester base film (usually referred to as Mylar). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Description and Operation > Page 11555 Instrument Panel Circuit Board: Service and Repair REMOVAL WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF IMPROPERLY HANDLED. WEAR EYE PROTECTION WHEN REPLACING ILLUMINATION BULBS. CAUTION: If gauges are being removed from the cluster assembly, do not remove the gauge pointers. Magnetic gauges cannot be recalibrated. 1. Remove the instrument cluster; refer to Instrument Panel. 2. Remove the illumination and indicator bulbs; refer to Warning Indicator Bulb. 3. Remove the gauges; refer to Gauges. 4. Remove the nineteen instrument gauge clips. NOTE: Do not reuse instrument gauge clips. 5. Remove the instrument cluster printed circuit. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations > Page 11559 Instrument Panel Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations > Page 11560 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations > Page 11561 Instrument Panel Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations Panel Illumination Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 11565 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 11566 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 11567 Panel Illumination Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 11568 Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 11569 Panel Illumination Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster Low Fuel Lamp/Indicator: Description and Operation Instrument Cluster NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. When the fuel level drops to a predetermined level, the CHECK GAGE indicator will illuminate. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster > Page 11577 Low Fuel Lamp/Indicator: Description and Operation Information and Message Center This warning message is displayed when there is approximately 80 km (50 miles) or less left before the vehicle runs out of fuel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 11578 Low Fuel Lamp/Indicator: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 11582 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation A million-mile tamper-resistant odometer is standard. Replacement speedometers have an odometer that can be reset to indicate correct vehicle mileage. NOTE: Some state laws require that the odometer in any replacement speedometer must register the same as on the removed odometer. Replacement speedometers and odometer modules with the mileage preset are available through Ford electronic repair centers. If the actual vehicle mileage cannot be determined, the repair centers are able to supply odometers set to "0" miles. An odometer mileage sticker is supplied with the replacement odometer. This sticker must display the estimated vehicle mileage and be affixed to the driver door jamb. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 11586 Odometer: Testing and Inspection To test the odometer accuracy, drive the vehicle over a measured distance of at least 16 consecutive kilometers (10 mile). Check measured distance against odometer measured distance. Acceptable odometer measured distance is 15.5 - 16.7 km (9.6 - 10.4 mile). For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. - When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: - oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 11590 Oil Change Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 11591 Oil Change Reminder Lamp: Service and Repair Oil Change Reset Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of 12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL CHANGE RESET control for five seconds. The message center will count down for five seconds. After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have established a personalized oil reset percentage, the display will show that percentage instead of 100%.) This reset procedure should be performed only after an oil change to ensure accurate oil life indications. Your personalized oil reset percentage allows you to establish a smaller oil change interval than the manufacturer's recommended interval. To establish your personalized oil reset percentage: 1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display is still counting gown the five seconds to reset. The display will change to START OIL LIFE AT XXX%. 2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil reset percentage you desire. Your choices are 100%, 90%, 80%, 70%, 60%, 50% 40% and 30%. 3. Press the RESET control to complete the procedure. Pressing any control other than RESET of OIL CHANGE RESET will abort this procedure and will not establish your new personalized oil reset percentage. When your personalized oil reset percentage has been established, it will be used beginning with the completion of your next OIL CHANGE RESET procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations > Page 11598 Oil Pressure Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 12-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 11602 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 11603 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 11604 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 11609 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations > Page 11613 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Service and Repair Parking Assist Warning Indicator: Service and Repair REMOVAL 1. Remove the LH quarter trim panel. 2. Remove the parking aid speaker. 1 Disconnect the electrical connector. 2 Remove the pin-type retainers. 3 Remove the parking aid speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11623 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11624 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11625 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11626 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11627 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11628 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11629 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11630 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11631 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11632 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11633 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11634 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11635 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11636 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 11637 Audible Warning Device Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 11638 Audible Warning Device Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 11639 Audible Warning Device Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation Fuel Gauge Module: Description and Operation NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 11643 Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 11644 Fuel Gauge Module: Service and Repair Service and Repair The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and must be replaced as a set. For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 11648 Instrument Panel Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 11649 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 11650 Instrument Panel Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations Panel Illumination Control Module: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 11654 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 11655 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 11656 Panel Illumination Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 11657 Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 11658 Panel Illumination Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 11662 Seat Belt Reminder Lamp: Description and Operation The safety belt warning indicator is powered through the GEM/CTM module. When the ignition key is turned on, the indicator illuminates for four to eight seconds even if the safety belt is buckled. For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 11663 Seat Belt Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 11668 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 11672 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 11676 Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 11677 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 11684 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Locations > Page 11688 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Locations > Page 11692 Speedometer Head: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations > Page 11696 Tachometer: Description and Operation The tachometer is a 6000 rpm tachometer. It has four terminals: one labeled B (12 to 1 4.5V), one labeled S (EDIS tach signal in), and two labeled G (cylinder selection grounds). The bottom ground (G) terminal is grounded. The top ground (G) terminal is grounded through a 4.32 kohm resistor in a 6-cylinder engine vehicle and is connected directly to ground for an 8-cylinder engine vehicle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations > Page 11697 Tachometer: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations > Page 11701 Temperature Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. 1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C104, circuit 39 (RD/WH), and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid range. Key OFF. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations > Page 11702 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See: Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 8-18 ft.lb Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 11706 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11717 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications Reversing Lamp Switch: Specifications Backup Lamp Switch 25-35 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 11722 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 11723 Reversing Lamp Switch: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 11724 Reversing Lamp Switch: Service and Repair REMOVAL 1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11733 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11739 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative Electronic Brake Control Module: All Technical Service Bulletins Speedometer/Odometer Inaccurate/Inoperative Article No. 99-26-4 12/27/99 SPEEDOMETER - INACCURATE SPEEDOMETER READINGS FORD: 1998-2000 EXPLORER, MOUNTAINEER, RANGER This TSB article is being republished in its entirety to include 2000 model year vehicles. ISSUE The vehicle odometer/speedometer may be inoperative or inaccurate as well as Malfunction Indicator Lamp (MIL) illuminated after the Generic Electronic Module (GEM), Central Timer Module (CTM), or the 4-Wheel Anti-lock Brake System (4WABS) Module has been replaced. This may be caused by either the GEM, CTM, or the 4WABS Module tire and axle size calibration. ACTION Reprogram the GEM, CTM, or 4WABS Module to match the vehicle attributes. Refer to the following Service Procedure for details. SERVICE PROCEDURE In the event a 1998 through 2000 Ranger GEM/CTM/4WABS or a 1998 through 2000 Explorer/Mountaineer 4WABS/C TM component requires service or replacement, the module(s) must be configured for proper operation using a New Generation Star (NGS) Tester and version 6.0 Service function card. If you do not have version 6.0 loaded, use the latest version Service Bay Technical System (SBTS) CD to download NGS Service Function Card Version 6.0 software to the green NGS service card for configuring modules. To configure modules, follow these instructions: 1. SELECT: SERVICE BAY FUNCTIONS 2. SELECT: GEM, CTM or ABS 3. For ABS, proceed to Step 4. For GEM or CTM, SELECT: CUSTOMER PREFERENCES 4. SELECT: TIRE SIZE/AXLE RATIO CONFIGURE a. The NGS Tester will display "DETERMINING MODULE PROTOCOL, PLEASE WAIT" b. When NGS Tester is ready, press {TRIGGER} to continue. 5. ENTER TIRE SIZE/REVOLUTIONS PER MILE (REV/MILE) NOTE THE TIRE SIZE MUST BE ENTERED AS A REV/MILE CALCULATION. REFER TO THE REV/MILE CHART FOR THE CORRECT CALCULATION. 6. ENTER AXLE/TONE RING SIZE NOTE Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 11745 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 99-26-4 > Dec > 99 > Speedometer/Odometer - Inaccurate/Inoperative > Page 11751 4X2 RANGERS EQUIPPED WITH A 2.5L OR 3.0L ENGINE HAVE A 7.5" AXLE. 4X4 AND 4.0L RANGERS HAVE AN 8.8" AXLE. ALL EXPLORERS/MOUNTAINEERS HAVE AN 8.8" AXLE. IF THE SPECIFIC AXLE CANNOT BE SELECTED, ENTER THE AXLE TONE RING TOOTH SIZE USING (00102) FOR 7.5" AXLES AND (00108) FOR 8.8" AXLES. 7. ENTER OPTIONS NOTE SELECT 4WABS, RABS, OR NA (IF NOT EQUIPPED). 8. ENTER VEHICLE 9. SELECT: DONE - The NGS Tester will display "MODULE CONFIGURATION COMPLETE." The module is now properly configured. Press {TRIGGER} to exit. 10. Verify with road test. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 992604A Reprogram Generic 0.7 Hr. Electronic Module (GEM), Central Timer Module (CTM), Or 4-Wheel Anti-Lock Brake System (4WABS) Module DEALER CODING CONDITION BASIC PART NO. CODE 14B205 42 2C219 42 OASIS CODES: 201000, 201100, 202000, 204000, 204200, 205000, 206000, 290000, 301000, 508000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11754 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11755 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11756 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11757 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11758 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11759 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11760 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11761 Brake Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11762 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11763 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11764 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11765 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11766 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11767 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11768 Brake Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11771 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11772 Brake Lamp: Pinpoint Tests J1 - J2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11773 J3 - J4 Test K: One or More Stoplamps Are Inoperative Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11774 K1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11775 K2 - K3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11776 K4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 11777 73 Digital Multimeter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11781 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11782 Brake Light Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11783 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the brake pedal position (BPP) switch connector. 2. Remove the BPP switch 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair Cargo Lamp: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lamp assembly. 1 Use a thin bladed tool to carefully pry the lamp assembly to the left. 2 Press the locking tab inward. 3 Lower the lamp assembly. 4 Disconnect electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling High Mounted Stoplamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 11795 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling High Mounted Stoplamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11801 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 11802 High Mounted Stoplamp: Specifications High Mounted Stoplamp Nuts 2.7-3.7 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 11803 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 11804 High Mounted Stoplamp: Service and Repair REMOVAL 1. Remove the liftgate glass. Refer to Windows. 2. Remove the plugs. 3. Remove the nuts. 4. Remove the high-mounted stoplamp. 1 Disconnect the electrical connector. 2 Remove the high-mounted stoplamp. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the interior lamp switch electrical connector. 2 Remove the interior lamp switch. ^ Push inward; rotate counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolts 3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 11813 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 11814 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 11815 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the daytime running lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Page 11819 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11823 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11824 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since the last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor only select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Input: ^ Sleep/awake mode status. Feature Output: ^ Battery saver relay control (open circuit in sleep mode, grounded when awake). For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11825 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11826 Battery Discharge Protection Relay: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Rear Domelamp Assembly Dome Lamp: Service and Repair Rear Domelamp Assembly REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lamp assembly. 1 Use a thin bladed tool to carefully pry the lamp assembly to the left. 2 Press the locking tab inward. 3 Lower the lamp assembly. 4 Disconnect electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Rear Domelamp Assembly > Page 11831 Dome Lamp: Service and Repair Front Domelamp Assembly REMOVAL 1. Disconnect the battery ground cable. 2. Use a thin bladed tool to carefully pry the dome lamp lens out. ^ Replace the bulb if necessary. 3. Remove the screws and lower the lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11835 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 11839 Exterior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 11840 Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 11841 Exterior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11846 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications Fog/Driving Lamp Switch: Specifications Fog Lamp Switch Mounting Bezel Screws 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 11850 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 11851 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 11852 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 3 Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 11853 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 11858 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 11862 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 11863 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 11864 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 11865 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions Headlamp Bulb: Service Precautions WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 11870 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn the headlamps on with the bulb removed. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb retainer counterclockwise and remove. 3. Remove the headlamp bulb. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: ^ Never turn the head lamps on with the bulb removed. ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Relay > Component Information > Locations > Page 11874 Headlamp Dimmer Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11878 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11879 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11880 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 11881 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 11885 Headlamp Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 11886 other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Specifications Main Light Switch: Specifications Head Lamp Switch Screws 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Specifications > Page 11890 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Main Light Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11893 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11894 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11895 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11896 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11897 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11898 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11899 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11900 Main Light Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11901 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11902 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11903 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11904 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11905 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11906 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 11907 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 11908 Main Light Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 11909 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 11910 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening cover reinforcement; refer to Dashboard. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the cluster instrument panel finish panel. 5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 11911 6. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11916 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11917 Horn Relay: Testing and Inspection Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11918 ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn blow switches are underneath the driver side air bag module in the steering wheel. The switches are powered through the air bag sliding contact and ground through the steering column. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Page 11922 Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag; refer to Air Bag Systems. 2. Remove the switches. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the attaching bolts from the switches and remove the switches. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11928 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11929 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11930 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11931 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11932 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11933 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11934 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11935 Illuminated Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11936 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11937 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11938 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11939 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11940 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 11941 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 11942 Illuminated Entry Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 11943 Illuminated Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 11944 Illuminated Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11948 Interior Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11953 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11954 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11955 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11956 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11957 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11958 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11959 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11960 License Plate Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11961 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11962 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11963 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11964 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11965 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11966 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11967 License Plate Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 11968 License Plate Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Parking Lamp; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11976 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11977 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11978 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11979 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11980 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11981 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11982 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11983 Marker Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11984 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11985 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11986 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11987 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11988 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11989 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11990 Marker Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 11995 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12001 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since the last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor only select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Input: ^ Sleep/awake mode status. Feature Output: ^ Battery saver relay control (open circuit in sleep mode, grounded when awake). For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12002 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12003 Battery Discharge Protection Relay: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolts 3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 12007 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 12008 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 12009 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the daytime running lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 12013 Exterior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 12014 Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 12015 Exterior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 12019 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations > Page 12023 Headlamp Dimmer Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 12027 Headlamp Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 12028 other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 12032 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 12033 Horn Relay: Testing and Inspection Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 12034 ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12040 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12041 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12042 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12043 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12044 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12045 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12046 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12047 Illuminated Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12048 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12049 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12050 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12051 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12052 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 12053 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 12054 Illuminated Entry Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 12055 Illuminated Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 12056 Illuminated Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 12060 Interior Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 12064 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 12072 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications Reversing Lamp Switch: Specifications Backup Lamp Switch 25-35 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 12076 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 12077 Reversing Lamp Switch: Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Specifications > Page 12078 Reversing Lamp Switch: Service and Repair REMOVAL 1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 12082 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 12083 Brake Light Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 12084 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the brake pedal position (BPP) switch connector. 2. Remove the BPP switch 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12093 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12094 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12095 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12096 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12097 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12098 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12099 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12100 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12101 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12102 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12103 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 12104 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: Customer Interest Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 12110 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 12116 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12121 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12122 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12123 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12124 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12125 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12126 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12127 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12128 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12129 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12130 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12131 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12132 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 12138 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12144 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12145 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12146 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12147 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12148 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12149 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12150 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12151 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12152 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12153 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12154 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12155 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 12156 Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 12157 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 12161 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications Fog/Driving Lamp Switch: Specifications Fog Lamp Switch Mounting Bezel Screws 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 12165 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 12166 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 12167 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 3 Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 12168 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 12172 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 12173 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 12174 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 12175 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 12179 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 12180 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 12181 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 12182 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Specifications Main Light Switch: Specifications Head Lamp Switch Screws 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Specifications > Page 12186 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Main Light Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12189 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12190 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12191 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12192 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12193 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12194 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12195 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12196 Main Light Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12197 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12198 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12199 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12201 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12202 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 12203 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 12204 Main Light Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 12205 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 12206 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening cover reinforcement; refer to Dashboard. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the cluster instrument panel finish panel. 5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 12207 6. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn blow switches are underneath the driver side air bag module in the steering wheel. The switches are powered through the air bag sliding contact and ground through the steering column. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 12211 Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag; refer to Air Bag Systems. 2. Remove the switches. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the attaching bolts from the switches and remove the switches. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the interior lamp switch electrical connector. 2 Remove the interior lamp switch. ^ Push inward; rotate counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 12218 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 12219 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 12220 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 12221 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 12222 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 12223 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 12228 OASIS CODES: 201000, 201200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Rear lamp Assembly Screws 1.6-2.2 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications > Page 12232 Exterior Lighting System Components Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12235 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12236 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12237 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12238 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12239 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12240 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12241 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12242 Tail Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12243 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12244 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12245 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12246 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12247 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12248 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12249 Tail Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 12250 Tail Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Parking Lamp; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 12251 Tail Lamp: Service and Repair REMOVAL 1. Raise the liftgate and remove the rear lamp screws. 2. Remove the rear lamp. Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting system of the vehicle is operating properly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 3 (7.5 A) ^ CJB Fuse 7 (7.5 A) ^ CJB Fuse 30 (15 A) ^ Loose or corroded connections ^ Damaged circuity ^ Damaged relays ^ Failed bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12256 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12257 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. AA1 - AA2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12258 AB1 - AB2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12259 AC1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12260 AD1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12261 AE1 - AE2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12262 73 Digital Multimeter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12272 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12273 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12274 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12275 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12276 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12277 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12278 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12279 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12280 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12281 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12282 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12283 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-6 > May > 00 > Windshield Wipers Operate While Switch is OFF Multifunction Switch: Customer Interest Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-6 > May > 00 > Windshield Wipers Operate While Switch is OFF > Page 12289 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 12295 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12300 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12301 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12302 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12303 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12304 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12305 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12306 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12307 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12308 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12309 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12310 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12311 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Multifunction Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 12317 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12323 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12324 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12325 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12326 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12327 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12328 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12329 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12330 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12331 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12332 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12333 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 12334 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 12335 Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 12336 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Turn Signal Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the turn signal/hazard flasher lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12344 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12345 Turn Signal Lamp: Pinpoint Tests L1 - L2 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12346 L3 - L4 Test M: Hazard Flasher Lamps Are Never ON Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12347 M1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12348 M2 - M3 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12349 M4 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12350 N1 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12351 Turn Signal Lamp: Component Tests and General Diagnostics Refer to Vehicle/Diagrams for schematic and connector information. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12352 Special Service Tool(s) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 12359 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 12360 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 12361 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 12362 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 12363 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 12364 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 12370 OASIS CODES: 201000, 201200 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair Vanity Lamp: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the sun visor. ^ Position the sun visor as necessary. ^ Remove the sun visor screws. 3. Lower the sun visor and disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 12379 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 12380 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 12381 Schematic Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 12389 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 12390 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 12391 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 12392 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 12393 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 12398 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 12399 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 12400 Schematic Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12406 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12407 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12408 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12409 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12410 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12411 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12412 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12413 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12414 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12415 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12416 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12417 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12418 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12419 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 12420 Power Window Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 12421 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 12422 Power Window Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 12426 Power Window Relay: Description and Operation LH Front Window Regulator Control Switch Inputs Table The GEM controls manual down and OTD window movement with the OTD relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 12427 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch 2 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 12437 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 12438 4 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 12439 Power Window Switch: Description and Operation The window regulator control switch: ^ Is located on each door trim panel. ^ May be used to raise or lower both LH side and RH side windows from the master control on the driver door. ^ Includes a window lock feature that is controlled through the master control. ^ Can manually lower the driver side window when the master control is depressed longer than 0.4 seconds. ^ The driver side window can be completely lowered when the master control is depressed between 0.04 and 0.4 seconds and then released. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12442 Terminals Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12443 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12444 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12445 Power Window Switch: Testing and Inspection Power window Switch Right Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12446 Schematic Left Rear Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12447 Terminals Schematic Right Rear Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12448 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12449 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door Power Window Switch: Service and Repair Driver Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. 3. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 4. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 12452 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 12453 Power Window Switch: Service and Repair Rear Door REMOVAL 1. Remove the rear window regulator switch plate. 1 Remove the screws. 2 Remove the rear window regulator switch plate. 2. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 3. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 12454 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12461 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12462 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12463 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12464 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12465 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12466 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12467 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12468 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12469 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12470 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12471 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12472 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12473 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12474 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 12475 Power Window Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 12476 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 12477 Power Window Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications Front Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 12482 Front Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 12483 Front Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 12484 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 12485 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 12486 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 12487 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications Rear Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 12491 Rear Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 12492 Rear Door Window Motor: Service and Repair REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Disconnect the battery ground cable. 3. Remove the rear door trim panel. 4. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Remove the power window motor. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the power window motor. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 12493 1. To install, reverse the removal procedure. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 12494 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 12498 Power Window Relay: Description and Operation LH Front Window Regulator Control Switch Inputs Table The GEM controls manual down and OTD window movement with the OTD relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 12499 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch 2 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 12505 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 12506 4 Door Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 12507 Power Window Switch: Description and Operation The window regulator control switch: ^ Is located on each door trim panel. ^ May be used to raise or lower both LH side and RH side windows from the master control on the driver door. ^ Includes a window lock feature that is controlled through the master control. ^ Can manually lower the driver side window when the master control is depressed longer than 0.4 seconds. ^ The driver side window can be completely lowered when the master control is depressed between 0.04 and 0.4 seconds and then released. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12510 Terminals Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12511 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12512 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12513 Power Window Switch: Testing and Inspection Power window Switch Right Front Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12514 Schematic Left Rear Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12515 Terminals Schematic Right Rear Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12516 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 12517 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door Power Window Switch: Service and Repair Driver Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. 3. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 4. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 12520 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 12521 Power Window Switch: Service and Repair Rear Door REMOVAL 1. Remove the rear window regulator switch plate. 1 Remove the screws. 2 Remove the rear window regulator switch plate. 2. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 3. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 12522 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. NOTE: Lower the window glass to access the two rivets. 4. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the front door. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 12527 INSTALLATION 1. Position the front door window glass. NOTE: Slide the glass through the outboard side of the front door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the front door trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Disconnect the two rear window defogger electrical connectors (one on each side). 3. Disconnect the two liftgate cylinders (one on each side). 4. Release the upper liftgate trim panel clips to gain access to liftgate window glass access plugs. 5. Remove the liftgate glass hinge access plugs. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 12531 6. Remove the liftgate window glass. 1 Remove the two liftgate window glass to window hinge nuts. 2 Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Movable Quarter Quarter Window Glass: Service and Repair Movable Quarter REMOVAL 1. Remove the quarter trim panel. 2. Remove the quarter window glass. 1 Remove the nuts. 2 Remove the quarter window glass. INSTALLATION 1. To install, reverse the removal procedure. NOTE: If the seal requires adjustment, disconnect the quarter trim panel. Rotate the quarter window latch clockwise to increase seal pressure or counterclockwise to reduce seal pressure. Reconnect the quarter window latch. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Movable Quarter > Page 12536 Quarter Window Glass: Service and Repair Quarter REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear quarter window glass. 1 Remove the ten nuts. 2 Carefully push the rear quarter window glass outward to release the butyl seal. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 6 mm (0.23 in) foam butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. ^ Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Tighten the ten nuts to specification. NOTE: Loosely install the ten nuts before tightening. 3. Install the quarter trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. 4. Remove the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 12540 1. Position the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the rear door trim panel. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications Front Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 12545 Front Door Window Regulator: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 12546 Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS Motor and Window Regulator - Front Door REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 12547 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 12548 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 12549 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 12550 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 12554 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the rear door trim panel. 2. Disconnect the inside rear door handle from the rear door. 1 Remove the screws. 2 Disconnect the inside rear door handle. 3. Disconnect the rod from the inside rear door handle. 4. Remove the speaker. 1 Remove the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 12555 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Raise and support the rear door window glass to the full up position. 7. Disconnect the battery ground cable. 8. If equipped, disconnect the power window electrical connector. 9. Drill out the window regulator rivets. 10. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 12556 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 12557 Heavy Duty Riveter Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information Windshield: Technician Safety Information WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 12562 Windshield: Vehicle Damage Warnings CAUTION: ^ If the vehicle is to be driven within 24 hours of urethane application, urethane sealant Essex U-216 must be used due to its one hour cure time. ^ After installing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12 - 24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane may adversely affect the strength of the urethane bond. ^ Do not scratch the pinch weld area. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12563 Windshield: Description and Operation Windshield Glass The windshield glass: ^ Is standard plastic and glass laminate safety glass. ^ Is bonded to the window opening flange with urethane sealant. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12564 Windshield: Service and Repair SPECIAL SERVICE TOOLS REMOVAL WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. 1. Remove the windshield side garnish moldings. 2. Remove the interior rear view mirror. For additional information, refer to Mirrors. 3. If equipped, remove the overhead console. Refer to Interior Trim. 4. Remove the sun visors. 1 Remove the sun visor screws. 2 Remove the sun visors. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12565 ^ If equipped, disconnect the electrical connector. 5. Remove the sun visor clips. 1 Remove the sun visor clip screws. 2 Remove the sun visor clips. 6. Lower the front portion of the headliner. 7. Remove the cowl grille. 8. Remove the upper windshield weatherstrip. 9. Remove the LH and RH windshield mouldings. 10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. 11. Using the special tool, cut the urethane sealant from the windshield glass starting at the top center and work toward the bottom corners. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12566 NOTE: Lubricate the urethane sealant with water to aid the special tool when cutting. 12. Using the special tool, distance the windshield from the body. 13. Using the special tool, cut the remaining urethane sealant and remove the windshield glass. 14. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. INSTALLATION CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12 - 24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane may adversely affect the strength of the urethane bond. 1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil. 2. Trim the remaining urethane sealant on the pinch weld to within the specification. ^ The existing urethane sealant surface should be smooth and free of cuts and contamination. CAUTION: Do not scratch the pinch weld area. 3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12567 4. Apply (A) Foam Butyl meeting Ford specification WSB-M2G234-C to the (B) pinch weld. 5. If reinstalling original windshield, remove the excess urethane sealant from the windshield glass. 6. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic coated area is clean. 7. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be urethaned. NOTE: Wipe off the Glass Prep immediately after each application because it flash dries. 8. Apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the pervious step. Allow five minutes to dry. 9. Cut the urethane applicator tip to specification. 10. Apply a bead of urethane sealant Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B to the pinch weld just outside the foam dam. CAUTION: If the vehicle is to be driven within 24 hours of urethane application, urethane sealant Essex U-216 must be used due to its one hour cure time. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12568 11. Install the windshield glass aligning it to the marks previously made. 12. After the windshield glass is set , check for water leaks and add urethane sealant where needed. 13. Install the upper windshield weatherstrip. 14. If necessary, remove excess urethane from the outside surface of the windshield glass. 15. Install the LH and RH windshield mouldings. 16. Install the cowl grille. 17. If equipped, install the overhead console. 18. Install the sun visor clips. 1 Install the sun visor clips. 2 Install the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12569 19. Install the sun visors. 1 Install the sun visors. ^ If equipped, connect the electrical connector. 2 Install the screws. 20. Install the front portion of the headliner. 21. Install the interior rear view mirror. For additional information, refer to Mirrors. 22. Install the windshield side garnish mouldings. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 12570 Windshield: Tools and Equipment SPECIAL SERVICE TOOLS Foam Butyl .......................................................................................................................................... ........................................................ WSB-M2G234-C Urethane Glass Prep Essex U-401 .............................................................................................................................................................. WSB-M2G314-B Urethane Glass Primer Essex U-402 ........................................................................................................................................................... WSB-M5B280-C Urethane Metal Primer Essex U-413 .......................................................................................................................................................... WSB-M2G234-C Urethane Sealant Essex U-216 ............................................................................... ..................................................................................... WSB-M2G316-B Urethane Sealant Essex 400-HV ................................................................................................................................................ ................. WSB-M2G316-B Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Locations Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12581 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12582 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12583 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12584 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12585 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12586 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12587 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12588 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12589 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12590 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12591 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12592 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12593 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12594 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 12595 Windshield Washer Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 12596 Windshield Washer Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 12597 Windshield Washer Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 12602 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 12603 Windshield Washer Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 12604 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12610 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12611 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12612 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12613 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12614 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12615 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12616 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12617 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12618 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12619 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12620 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12621 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12622 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12623 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 12624 Wiper Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 12625 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 12626 Wiper Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12631 Wiper Relay: Locations Rear Wiper Up Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12632 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12633 Wiper Relay: Locations Rear Wiper Down Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12634 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12635 Wiper Relay: Locations Wiper High Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12636 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12637 Wiper Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12638 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12639 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12640 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12641 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12642 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12643 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12644 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12645 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12646 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12647 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12648 Wiper Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12649 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Windshield Wiper Washer Switch 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 12654 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch Windshield Washer Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 12657 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12658 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12659 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12660 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12661 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12662 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12663 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12667 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 12670 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12671 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12672 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12673 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12674 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch Wiper Switch: Service and Repair Rear Wiper Switch REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the two screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12677 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12678 Wiper Switch: Service and Repair Multifunction Switch Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12679 2 Remove the upper and lower steering column shrouds. 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation This warning message is displayed when there is less than one quarter of the container of washer fluid remaining ^ When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close, grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator. ^ When the washer fluid level is low, the input to the message center indicator will be open and the warning will be displayed. The message center indicator filters this input therefore, there will be a 20-second delay before the warning is displayed or removed. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12688 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12689 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12690 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12691 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12692 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12693 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12694 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12695 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12696 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12697 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12698 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12699 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12700 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12701 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 12702 Windshield Washer Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 12703 Windshield Washer Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 12704 Windshield Washer Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations Rear Washer Hose Location And Routing Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations > Page 12708 Windshield Washer Hose: Description and Operation Wipers and Washers-Rear Washer Hose Fluid for the rear washer is supplied by a two-way washer pump located in the windshield washer fluid reservoir in the engine compartment. The rear washer hose contains a check valve, which is located in the hose that passes through the liftgate in the rear of the vehicle. This check valve holds the entire line full of washer fluid between washer operation. There is also a stand pipe located along the right hand D-pillar of the vehicle. This stand pipe prevents the unintentional release of washer fluid from the rear washer nozzle. If the hose is cut or disconnected after the line was initially primed with fluid, and the washer system is turned on, the stand pipe may fill with fluid. To resolve this, once the hose is repaired, temporarily disconnect the check valve to allow fluid in stand pipe to drain to lowest point in the hose; then reinstall the check valve. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations > Page 12709 Windshield Washer Hose: Service and Repair 1. Locate and verify the leaking washer hose. 2. Cut the hose cleanly and remove the damaged portion of the washer hose. 3. Install a windshield washer hose adapter between the cut ends of the hose. 4. Install a segment of 6.4 mm (0.25 in) i.d. black rubber hose N809610-S or equivalent over the ends of the washer hose, and clamp both ends of the rubber hose using spring clamps 389252-S101 or equivalent. NOTE: In difficult cases, clamping may be required. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Wiper And Washer Systems Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 12713 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect the windshield washer hose from the windshield washer pump. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. 2. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the outlet of the reservoir. 3. Disconnect the windshield washer reservoir pump electrical connector and low level washer fluid electronic sensor connector, if equipped. 4. Remove the engine air cleaner; refer to Fuel Delivery and Air Induction. 5. Remove the two screws and two nuts and remove the windshield washer reservoir. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 12714 6. Remove the windshield washer pump. NOTE: Make sure not to tear the rubber grommet during disassembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The windshield washer reservoir, windshield washer pump and the windshield washer reservoir fluid level sensor are replaced separately. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 12719 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 12720 Windshield Washer Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 12721 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Wiper/Washer Reservoir Screw and Nut 5-6 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 12725 Wiper And Washer Systems Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 12726 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect the windshield washer hose from the windshield washer pump. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. 2. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the outlet of the reservoir. 3. Disconnect the windshield washer reservoir pump electrical connector and low level washer fluid electronic sensor connector, if equipped. 4. Remove the engine air cleaner; refer to Fuel Delivery and Air Induction. 5. Remove the two screws and two nuts and remove the windshield washer reservoir. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 12727 6. Remove the windshield washer pump. NOTE: Make sure not to tear the rubber grommet during disassembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The windshield washer reservoir, windshield washer pump and the windshield washer reservoir fluid level sensor are replaced separately. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations Windshield Washer Spray Nozzle: Locations Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations > Page 12731 Wiper And Washer Systems Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Windshield Wiper Washer Switch 2-3 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 12735 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch Windshield Washer Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 12738 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12739 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12740 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12741 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12742 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12743 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 12744 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications PivotArm-RearNut 13-17 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 12748 Wiper Arm: Locations Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 12749 Wiper And Washer Systems Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 12750 Wiper Arm: Service Precautions CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front Wiper Arm: Service and Repair Pivot Arm-Front REMOVAL 1. Remove the pivot arm. 1 Pull upon the pivot arm. 2 Pull out on the retainer tab and remove the pivot arm. NOTE: The windshield wiper pivot arms are replaced as an assembly. INSTALLATION 1. To install. reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 12753 Wiper Arm: Service and Repair Pivot Arm-Rear REMOVAL CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the procedure. 1. Disconnect the rear washer hose. 2. Remove rear pivot arm. 1 Lift the pivot arm nut cover. 2 Remove the nut. 3 Remove the pivot arm. INSTALLATION 1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 12754 2. Turn the rear wiper switch OFF. NOTE: This step ensures that the wiper motor is in the park position. 3. Position the wiper blade outside the wiper arm stop. 4. Install the wiper pivot arm onto the wiper motor. ^ Tighten retaining nut. 5. Connect the washer hose. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 12755 6. Cycle the wiper motor one time to allow the wiper arm to park on the wiper arm stop. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Locations Wiper Blade: Locations Wiper And Washer Systems Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Locations > Page 12759 Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12765 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12766 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12767 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12768 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12769 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12770 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12771 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12772 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12773 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12774 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12775 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12776 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12777 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12778 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 12779 Wiper Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 12780 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 12781 Wiper Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Rear Wiper Motor Bolts 9-12 Nm Windshield Wiper Motor Bolts 7.0-9.0 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 12785 Wiper Motor: Locations Wiper And Washer Systems Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 12786 Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 12787 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 12788 Wiper Motor: Service Precautions CAUTION: ^ Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the wiper motor inoperative. Rough handling of new replacement wiper motors may also damage the motor magnets. ^ The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. ^ To avoid possible damage to the mounting arm and pivot shaft retainer clip, be sure the clip is fully seated before installing on the motor crank pin. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 12789 Wiper Motor: Testing and Inspection CAUTION: Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the wiper motor inoperative. Rough handling of new replacement wiper motors may also damage the motor magnets. Use Alternator, Regulator, Battery and Starter Tester (ARBST) to test the wiper motor on the vehicle. To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor; refer to Pivot Arm-Front or Pivot Arm-Rear. Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to the wiper motor (4) common brush terminal (terminal 3). Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, replace the windshield wiper motor. Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, replace the wiper motor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor Wiper Motor: Service and Repair Windshield Wiper Motor REMOVAL CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. NOTE: The windshield wiper motor is not a repairable item. If worn or damaged, the motor must be replaced. 1. Remove the LH pivot arm. 1 Pull upon the pivot arm. 2 Pull out on the retainer tab and remove the pivot arm. 2. Remove the LH cowl top vent panel screw. 3. Disconnect the washer hose from the LH washer jet nozzle. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 12792 4. Remove the LH cowl top vent panel. Release the seven spring retainers. 5. Unsnap the wiper motor clip from the RH mounting arm and pivot shaft. 6. Disconnect the RH windshield wiper mounting arm and pivot shaft from the LH windshield wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 7. Disconnect the electrical connector. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 12793 8. Remove the ground strap nut and position the strap aside. 9. Remove the windshield wiper motor. ^ Remove the stud bolts. ^ Remove the bolts. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 12794 1. To install, reverse the removal procedure. CAUTION: To avoid possible damage to the mounting arm and pivot shaft retainer clip, be sure the clip is fully seated before installing on the motor crank pin. NOTE: ^ Install the LH mounting arm and pivot shaft to the motor before installing the RH mounting arm and pivot shaft. ^ Install the retainer clip on the RH mounting arm and pivot shaft prior to installing the motor. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 12795 Wiper Motor: Service and Repair Rear Wiper Motor REMOVAL 1. Remove the rear pivot arm; refer to Pivot Arm-Rear. 2. Remove the liftgate door trim panel. 3. Position the watershield aside to gain access to the rear wiper motor. 4. Remove rear wiper motor. ^ Disconnect electrical connector. ^ Remove three retaining bolts. ^ Remove rear wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications Wiper Motor Linkage: Specifications Windshield Wiper Pivot Shaft Nut 10-13 Nm Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 12799 Wiper Motor Linkage: Service Precautions CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 12800 Wiper Motor Linkage: Service and Repair REMOVAL 1. Cycle the windshield wiper blades to the vertical position. 2. Remove the cowl top vent panels. 3. Unsnap the wiper motor clip from the RH mounting arm and pivot shaft. 4. Disconnect the RH windshield wiper mounting arm and pivot shaft from the LH windshield wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 5. Remove the RH and LH mounting arm and pivot shafts. 1 Remove the two nuts. 2 Remove the mounting arm and pivot shafts. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 12801 INSTALLATION 1. Install the RH and LH mounting arms and pivot shafts. 1 Position the mounting arm and pivot shafts into place. 2 Install the two nuts. 2. Install the clip onto the RH mounting arm and pivot shaft. CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. 3. Install the LH windshield wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin, and install the RH windshield wiper mounting arm and pivot shaft onto the wiper motor crank pin. 4. Install the cowl top vent panels. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page 12805 Wiper Motor Timer: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page 12806 Wiper Motor Timer: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page 12807 Wiper Motor Timer: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12812 Wiper Relay: Locations Rear Wiper Up Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12813 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12814 Wiper Relay: Locations Rear Wiper Down Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12815 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12816 Wiper Relay: Locations Wiper High Relay Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12817 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12818 Wiper Relay: Locations Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12819 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12820 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12821 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12822 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12823 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12824 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12825 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12826 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12827 Part (1 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper Run Relay > Page 12828 Part (2 Of 2) Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12829 Wiper Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12830 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Rear Wiper And Washer System Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12834 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 12837 Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12838 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12839 Component Testing Procedure Terminals Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12840 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 12841 Schematic Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch Wiper Switch: Service and Repair Rear Wiper Switch REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the two screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12844 1. To install, reverse the removal procedure. Ford Explorer 4wd Workshop Manual (V8-302 5.0L VIN P SFI (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12845 Wiper Switch: Service and Repair Multifunction Switch Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws.